1 9 92 CONTENTS: F Mazda General Information oe Cesare Tn B2600i fet 32200 Workshop Lubrication System Manual Cooling System Fuel and Emission | Carburetor Control Systems Eq) FOREWORD Engine Electrical System This workshop manual is intended for use by service technicians of Authorized Mazda | Clutch ‘Dealers to help them service Mazda vehicles. Fot ‘proper repair and maintenance, a | Manual thorough familiarization with this manualisim- | Tranemission portant, and it should always be kept in a han- dy place for quick and easy reference. | Teanater.Cese Al the contents of this manual, including drawings and spectications, are the latest avai able al the {ime of printing. As modifications | Automatic affecting tepair or maintenance occur, relevant | Transmission Carona information supplementary to this volume will be made available at Mazda dealers. This Transfer Case manual should be kept up-to-date. Propeller Shaft Mazda Motor Corporation reserves the right to alter the specifications and contents of this _| Front and Rear Axles manual without obligation or advance notice. esering Allrights reserved. No part of this bookmay | Steering System be reproduced or used in any form or by any | means, electronic or mecharical—inclucing _Br@king System photocopying and recording and the use of | Wheels and Tires any kind of information storage and retrieval system—without permission in writing, ‘Suspension Mazda Motor Corporation HIROSHIMA, HIMA, JAPAN | Gody Electrical System APPLICATION: This manual is applicable to vehicles beginning | Heater and Alr Conditioner Systems with the Vehicle Identification Numbers (VIN) | Teghnical Data shown on the following page. Special Tools Parts index Wiring Diagram {bere gopcany © 1991 Mazda Motor Corporation PRINTED IN USA, JUL. ‘91 1269-10-91G (8999-95-022B-92)VEHICLE IDENTIFICATION NUMBERS (VIN) JM2UF123 «NO 250001 ~ JM2UF223 «NO 250001 ~ JM2UF323 «NO 250001 ~ JM2UF113 *NO 250001 ~ JM2UF213 «NO 250001 ~ ‘JM2UF313 «NO 250001 ~ JM2UF114«NO 250001 ~ ‘JM2UF314%NO 250001 ~ JM2UF414*NO 250001 ~ JM2UF614*NO 250001 ~ JM2UF514%NO 250001 ~ ‘JM2UF223+NO 250001 ~ a =FGENERAL INFORMATION IMPORTANT INFORMATION BASIC ASSUMPTIONS. SAFETY RISK. POSSIBLE LOSS OF WARRANTY WARNING ON LUBRICANTS AND GREASES. HOW TO USE THIS MANUAL. PROTECTION OF THE VEHICLE .. A WORD ABOUT SAFETY esse PREPARATION OF TOOLS AND MEASURING EQUIPMENT ... SPECIAL TOOL! REMOVAL OF PARTS.. DISASSEMBLY . REASSEMBLY ADJUSTMENTS RUBBER PARTS JACK AND SAFETY STAND (RIGID POSITIONS. a VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS. TOWING.. WITH MANUAL TRANSMISSION, WITH AUTOMATIC TRANSMISSION CHASSIS NUMBER LOCATION. ENGINE MODEL AND NUMBER LOCATION .. ABBREVIATIONS CAUTION ELECTR TOOLS .. CAUTION WITH ELECTRICAL PARTS. ‘ssvarcoat Gl PO onGl IMPORTANT INFORMATION IMPORTANT INFORMATION BASIC ASSUMPTIONS This workshop manual assumes that you have certain special tools that are necessary for the safe and eff cient performance of service operations on Mazda vehicles and that you know how to use them properly Italso assumes that you are familar with automobile systems and basic service and repair procedures. You should not attempt to use this manual unless these assumptions are correct and you understand the conse- ‘quences described below. SAFETY RISK This manual contains certain notes, warnings, and other precautionary information that you should carefully read and follow to reduce the risk of personal injury to yourself or others and the risk of improper service that may damage the vehicle or render it unsafe. If there is no such information in regard to any specific service method, this does not mean there is no possiblity that personal safety or vehicle safety will be jeopardized by the use of incorrect methods o tools. POSSIBLE LOSS OF WARRANTY ‘The manufacturer's warranty on Mazda vehicles and engines can be voided if improper service or repairs are performed by persons other than those at an Authorized Mazda Dealer. WARNING ON LUBRICANTS AND GREASES Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated uring service (e.g., engine sump ails) are more irritating and more likely to cause serious effects, including skin cancer, in the event of gross and prolonged skin contact. ‘Wash skin thoroughly after work involving oil. Protective hand cleaners may be of value provided they can be removed from the skin with water. Do not use gasoline, paraffin, or other solvents to remove oil from the skin. Lubricants and greases may be slightly irritating to the eyes. Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particu lar care should be taken with used oils and greases containing lead. Do not allow work clothing to be con- taminated with oil. Dry clean or launder such clothing at regular intervals. sntusoc 002 GI-2 } SYGl HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL PREPARATION PREPARATION points cut the needed SST for the service operation that follows. Itis best to gather al necessary SST before beginning work. Gl Example: N ie-Rop END BOOT AND STEERING GEAR BOOT ‘SST NUMBER, ‘TIE-ROD END BOOT AND STEERING GEAR BOOT ‘ssT NAME SST ILLUSTRATION omveixoas REPAIR PROCEDURE 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and visual parts inspections. If a damaged or worn partis found, repair or replace it ‘as necessary. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview istration, 8, Pages related 10 service procedures are shown under the illustration. Refer to this information when ser- vicing the related part. Example: sows Fao sows 5 ee Rae | |e. ea a n | ae = Wy oe Bohr |\ a eee Ne Se mexaasy | ORG UT 2 lode See, ee ‘shows § Seerpg et tee INSPECTION RELATED Sis INFORMATION te ee rapt sins a eh waa Sats sence fA BEY“ Keuanent ot hog ‘pepe nae a fl The numbering (ex@)y shows service procedure. *2: Units shown in Nm (m-kg, ft-lb) unless otherwise specified. GI-3GI How To usE THIs MANUAL/FUNDAMENTAL PROCEDURES SYMBOLS There are 6 symbols for oil, grease, and sealant. These show the points of applying oil, grease, or sealant during servicing. a = = Wawa Wow rg o'r geo 2 eprptte Sou oe i oo 1. _— — ee ere ao o Apply petroleum jelly Appropriate petroleum jelly a Note When special oil or grease is needed, this is shown in the illustration. NOTES, CAUTIONS, AND WARNINGS {As you fead through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each ‘one is there for a specific purpose. NOTES give you added information that will help you to complete @ particular procedure, CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause per- sonal injury. The following list contains some general WARNINGS you should follow when you work on a vehicle, saavancoss FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor areas be- fore starting work. mEFUNDAMENTAL PROCEDURES Gl ava TOT ‘A WORD ABOUT SAFETY The folowing precautions must be folowed when jacking up the vehicle, 1. Block the wheels, 2. Use only the specied jacking postions 3. Support the vehicle wih safety stands Start the engine only after making certain the engine compart- ment is clear of tools and people. PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equipment are available before starting any work ‘SPECIAL TOOLS Use special tools when they are required. REMOVAL OF PARTS While correcting @ problem, try also to determine its cause. Begin work only after first learning which parts and subassem- blies must be removed and disassembled ior replacement or repair. DISASSEMBLY IWthe disassembly procedure is complex, requiring many parts to be disassembled, al parts shouid be disassembled ina way that will not affect their performance or external appearance {and identified so that reassembly can be periormed easly and efficiently GI-5FUNDAMENTAL PROCEDURES 1. Inspection of parts When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. ra 2. Arrangement of parts All disassembled parts should be carefully arranged for re- assembly, Be sure fo separate or otherwise identity the parts to be replaced from those that will be reused. mae Cleaning parts for reuse Al parts to be reused should be carefully and thoroughly cleaned in the appropriate method. REASSEMBLY Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE in Section TD for tightening torques not mentioned in the main text If removed, these parts should be replaced with new ones: 4. Oil seals 2. Gaskets 3. Orings 4, Lock washers 55. Cotter pins 6. Nylon nuts RARER Depending on location: 1. Sealant should be applied to gaskets. 2. Oil should be applied to the moving components of pats. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly. mao Gi-6FUNDAMENTAL PROCEDURES Gl ADJUSTMENTS Use suitable gauges and/or testers when making adjustments. RUBBER PARTS AND TUBING Prevent gasoline or ol from getting on rubber parts or tubing. GI-7Gl JACK AND SAFETY STAND (RIGID RACK) POSITIONS JACK AND SAFETY STAND (RIGID RACK) POSITIONS FRONT et Jack position: Safety stand positions: : At the center of the crossmember On both sides of the Jack point L EGO EROS \ 2 REAR Safety stand positions: Jack position: ‘On both sides of the ‘At the center of the differential diferential oy area oo Gi-8VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS Gl VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS FRONT Jack point: On both sides of the jack point AR Oo aq. TL % ie ; \ Bry BAY \ SA Eo Gi-9| gtategrleteee FOR au SEr THE REMOTE FREE WHEEL SYSTEM YO FREE MODE BUR TOWING TOWING Proper towing equipment is necessary to prevent damage to the vehicle during any towing operation. Laws and regulations applicable to vehicles in tow must always be observed. Release the parking brake, place the shift lever in neutral, anc set the ignition key in the ACC position. As a rule, towed vehi cles should be pulled with the driving wheels off the ground, WITH MANUAL TRANSMISSION If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels, it any of these components are damaged, use a towing dally WITH AUTOMATIC TRANSMISSION If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use a wheel dolly. With all 4 wheels on the ground, the vehicle may be towed only forward. In this case, do not exceed the following towing speed andlor distance or transmission damage could result we wa Toving speed 5 tanh G6 mph] | 66 ev 85 my “Towing tans 8 em (10-rites) —| 58 kr 5 rls) Ittowing speed andor distance will excead above-mentioned specifications, use one of three methods: 1, Place the rear wheels on a dolly 2. Tow with the rear wheels off the ground, 3. Disconnect the propeller shaft. (4x4: rear propeller shat) Ifthe transmission or rear axle is inoperative, tow the vehicle with its rear wheels off the ground or have the propeller shatt disconnected, CAUTION a) The power assist for the brakes is inoperable while the engine is off. b) When either of the towing hooks Is used, pull the cable or chain straight away from the hook and do not apply any sideways force to It. To further help prevent damage, do not take up slack too quickly in the cable or chain. ©) The rear towing hook should be used only in an emergency situation (for example, to pull the vehi- cle from a ditch, snow, or mud).CHASSIS & ENGINE NUMBER LOCATION/UNITS/ABBREVIATIONS. Gl CHASSIS NUMBER LOCATION UNITS Tm (kg Wb). Torque i Pareions per mine A Ampere(s) : von a Ot (estiance) 168 Want po) Prose (ual poet) mmtig (a He)... Presne (ety nog) Ie w Wa rm tenet Ta ENGINE MODEL AND NUMBER LOCATION ABBREVIATIONS Basoo! ETRBUTER 777 Se 186... Aer bolo dead car ABS. Antec eke avn & A0Attuootas & AiG AF conten, AV At conte A062 Aker op ea eer Mino Altona anarosen AE Alora aramid Sn Bypoo ar come BBD.” Bee oti Sead conor | Bio. Bote top das senor ECAT Ecvencabyconued sromate avarice EOU. Engi eae anh ED. Enegeaive ere conta oan EGR nnn Beha go touton Eu Emorgerby log eer EIR Beste Reg nae Bee ena Fg we PR Hiroe convoed erate weccicase HUA ou OE Lh eo heap cheat fac (ne Nam ane aR IN torment 180. sped cont So Rare 16. Lina a rete Was" our ade een Wi Mate ede nt A" Mant pera NF Macartney todo OB Ot agree OF Sten Se Sth on FEV Proeniing by pase vas Po polar sakes venoaion PB Power desing FEW" Ronee ee hoa hub Bee Riek han Sa Sete Ta te aut crow Toe top aed bance FPS eto toy iene aUaKoR Gi-11CAUTION ke aero “Se VOLTMETER aaa BaEKOe aca Gi-12 CAUTION ELECTRICAL TROUBLESHOOTING TOOLS Test Light ‘The test light, as shown in the figure, uses a 12V bulb. The two lead wires should be connected to probes. ‘The test light is used for simple voltage checks and for check ing for short circuits. Caution When checking the control unit, never use a bulb over 3.4W. Jumper Wire ‘The jumper wite is used for testing by shorting across switch terminals and ground connections. Caution Do not connect a jumper wire from the power source line to a body ground; this may cause burning or oth- er damage to harnesses or electronic components. Voltmeter The DC voltmeter is used to measure of circuit voltage. A vol meter with a range of 15V or more is used by connecting the postive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (-) probe {black lead wire) to a body ground, Ohmmeter ‘The ohmmeter is used to measure the resistance between two points ina circult and also to check for continuity and diagno- sis of short circuits. Caution Do not attempt to connect the ohmmeter to any cir- cuit to which voltage is applied; this may burn or other- wise damage the ohmmeter. CAUTION WITH ELECTRICAL PARTS Battery Cable Before disconnecting connectors or replacing electrical parts, disconnect the negative battery cable.CAUTION Gl eee = ra se ow » a EB RTT Connectors Removal of connector Never pull on the wiring harness when disconnecting con- neciors. Connectors can be removed by pressing or pulling the lock lever as shown, Locking of connector When locking connectors, make sure to listen for @ click that will indicate they are securely locked. Inspection When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wire harness side, Terminals Inspection Pull lightly on individual wires to check that they are secured in the terminal GI-13aaa \ CAUTION Replacement of terminals Use the appropriate tools to remove the terminal as shown. When installing the terminal, be sure to insert it until it locks Gay securely. Insert @ thin piece of metal from the terminal side of the con- nector, and then. with the terminal locking tab pressed down, pull the terminal out from the connector. Same as the female type. Wiring Hamess Wiring color codes Two-color wires are indicated by a two-color code symbol The firs letter indicates the base color ofthe wire and the sec- cond the color of the stripe. ~ (CODE ‘coLon cope | COLOR : 3 Bleck ° Orange BR Brown P Pok | 6 Green a Rea oy Gray v Vile t Bue w wre | 18 ont Bue ¥ Yellow is Light Green 7 = Sensors, Switches, and Relays Handle sensors, switches, and relays carefully. Do not drop them or strike them against other parts.BUS Eero CAUTION Gl Fuse Replacement 1. When replacing a fuse, be sure to replace it with one of specified capacity |'a fuse again fails after it hes been replaced, the circuit probably has @ short circuit and the wiring should be ‘checked. 2. Be sure the negative battery terminat is disconnected be- fore replacing a main fuse (804), 8. When replacing a pull out fuse, use the fuse puller supplied in the fuse box cover. GI-15PRE-DELIVERY INSPECTION AND SCHEDULED MAINTENANCE SERVICES PRE-DELIVERY INSPECTION .. PRE-DELIVERY INSPECTION TABL! SCHEDULED MAINTENANCE SERVI (USA)... « ‘SCHEDULE 4 {NORMAL DRIVING CONDITION) 82600) SCHEDULE 1 (NORMAL DRIVING CONDITION) 82200... A= 7 SCHED! (eNIovE ‘CaN CONDITION) B2600i.. SCHEDU (UNIQUE ‘DAIVING CONDITION) 82200 eos A> SCHEDULED MAINTENANCE SERVICES (CANADA) aesPRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE Following items may be done at any time prior to delivery to your customer. [4 EXTERIOR + INSPECT and, necessary, ADJUST the folowing tems to specications: 12 Gis, exarior bright metal, and paint for damage Gi Wheel tug nuts Nowsted 88-118 Ne» (0-120 mrtg, 6587 fe) Styiod! 118147 Nev (12.0—18.0 ekg, 87-106 tb) ‘Al waathorstips for damage ox detachment Overaton of haod release and lock 1D Operston 0! tua id opener (I eaupped) 5 Door oporeton and algnment 1 Heaigne arn * INSTALL tho folowing parts: i Wheel cantor caps ft equipped) 5 Outside rearview meron) 2. UNDER HOOD—ENGINE OFF * INSPECT and, necessary, ADJUST the folowing items 1 spectations: 1D Fue), coolant anc hydraulic ines, ftings, connections, and ‘components for leaks. Engine oF leve! 1 Ollfeval in steering gearbox 5 Power stoering fud level equipped) 1 Brake ana clutch master cylinder td levels 1D Windehlald washer resarvor fic level 1D Headlight cleaner reservor fd level (if equippec) 1D Raciator coolant level D Tightness of batiory terminals 3. INTERIOR = INSTALL the following pans: 1 Rubber stopper for inside rearview mirror © CHECK the operations of the folowing roms: 1D Seat coniros (siding and recining) and head rest 1D Boor Socks: 1D Foe-Down rear seats (Cab Pius only) ‘© Seat bets and warning system 5 Igaiton switch and steering iook Sartor interlock switch (MPT only) 5B Shitiock systen and inhibitor sutch (AIT only) D Al iat, Incucing warring anc incicator its (equipped) I Horn, windshield wipers, and washers (f equipped) 1D Headlight cloaner ( equipped) 5) Radio and antenna (i equipoec) 1 Cigaratie lighter and clock (f equippsc) INTERIOR (cont'd) i Healer, dose, and al conditioner at iferent modest eqarped + GREEK he folowing tems: D Fresence of spare fase 1 Upotsery and miro rich Following items must be done just before the delivery 1D Load test battery and charge if necessary vate 1B Adjust ire pressure tothe specification {Pater to Section Q) © Ciean outside of vehicie A-2 '» CHECK and, # necessary, ABMUST the folowing items: 1 Pedal ne ght Wah earoed and ree piay 0! breke and clutch pedal Pada heght mm Te] Free play mm (a) Caioh [BEBO [91207 (7527.8 ; pec) eze00 Her—rar g.1e=75q) °° $0028 Brake pedal 160185 (7 08—7.28)| 407.0 16-028) 1 Peting 660K wanna. 712 Nolchos!196N (20 kg, 44 Ib) UNDER HOOD—ENGINE RUNNING AT OPERATING TEMPERATURE 4 CHECK the falowing Heme: 5 Trois sere (€) 1 Operation of loleu system for. = Airconditoner and automete tranemission (Carburetor) 1D Automate transmission uid leve Ci Operation of dashpot (Carburetor & Carburetor oat level intial igntlon tering: 6 & 1° BTDC (82200) & Idle speed: 800 “Y rpm AT; in P range (82200) © Operation of EGR contral valve (Carburetor) 1D Operation of lole switch (Carburetor) ‘ON HOIST ‘CHECK tne folowing tems: B Operation of remota freewhee! (4x4 only) 5 Manuel varemiesion of level 1G Transfer oo89 ol love (4x4 oni) 1D Front ade a level (x4 only). 1 Rear axe oll evel 1H Underside fuel, coolant and hydraulic nes tings, connec- ‘ions and components for leaks 1D Tres for cuts or bruisos| U Stosting Invage, suspension, exhaust sytem and all under- side harcware for looseness or damage 6, ROAD TEST © CHECK ihe folowing tems: 1D Brake oporaton © Clutch operation 5) Steering control 1D Operation of metere and gauge 1D Squeaks, ratles of unusual noises | Emergency lock relractore 5 Cruse contol eyetom (it equippec) 1B Operation of ranster caso (4x4 ony) 7 AFTER ROAD TEST = CHECK for necessary owner's information material, tool ‘and spare te in vehicle to your customer. 1D Install fuses tor accessories [U1 Remove seat and foor mat protective covers 1D Vacuum and clean interior of vehicle 1B Inspect instalation of option pans with invelce eeuaaccozSCHEDULED MAINTENANCE SERVICES (USA) owo}ed eq O32 Tei PuewuIOD9: am “JOADMO}, "BWLOMED Klooxe SaIES Ife PUE ’pBUED 40} Poulnbe: S| coUEUEIUIEL SIL ¢, IOeINUEW 10 @BErGAOD AIUELsEM UO|SSHWWE 10} KtBSSBOSU JOU SI “OASMOH| "EPZEW Aq PapUeWUIOOEI s| BOUEUOINTEW SL ZL “SQUBUSTUIB PACLOSEp OY 167 sOTPO;PUY UOHOUNIEWY 94 ‘9IOIYOA BIUIOWED 10) OOK] L HO} 94) 910U “ueYD BOUEUO|UIEL SIM UI SWOY PEW , 10} Sy 10} 01 enuyuaD "(w4 000'96) SAIL OOO‘OR 40 SYUOW O9 JOMY TOMEWO ‘NO S8LUOO 1 41 ‘S9)tU O0'DR PU SA! QOO'O9 ArBne Ie NO SewWOD ‘Su ‘SJPAU9TUI PapUBWULOD! OY) JB BoUELETUIEW PequoseP eUL aBueyo 10 eoerdey e0exda1 10 Uvapp “joeu09 Aresseodu |) pure Joadsul ‘| ssjoquiks weus toosza (NOLUIGNOO ONIAIG TWAON) | 71NGSHOS “SeIEWYO Pluiny A]ELIE:Xe Jo/pue eunzesedwe plod Ul poad paBUO}OId e 404 BUIAU » ‘voyezedo peeds mo} J0/pue Gulp! jo spoued pepuoyx3 « “Joe © BUMOL ‘speoi Appnu so7pue YBN: UO BuIA « “SIeURTEL! OnI801I00 JeYO 40 es peoI BuIsN seOIe “uonpuod Ajsnp ul Bulg, ‘BUIAUP @OUe ISI LoYs peyeedey « (vonpuog Bunup anbun) z empetng uiAlc [SWHON) | ainpayog 84h MO] (vn) S3OIAUaS SONVNALNIVW G31NGaHOS :Aidde mojeq suogpUoD au Jo Aue 94 Mojo; AueAUOD -Afdde suoMIpUOD BuMoIO} oy) Jo BUOU e1o\/A peyeEdO AIUIEW SI EjOIYOA BUN 4! (UOMPUOS A-3SCHEDULED MAINTENANCE SERVICES (USA) g (eau re HED AM a a a ¥ wep outs |“ 3 1 U 1 u | woh Bu1000 = WAISAS ONTIOOS seed | soyexsavoduco puv sorcowwoa soins «|_| el sou erg | epimza “Ta 7a Gia ois gw we OBL—OB ales ‘iW wel 042-062 «ll el eds ap ‘baad OIL | | wa1SKS Tana | 1 SOL oS HH WORABT_« [1 a Buku VOR fn prepues. el ‘OSNAGNOdAIN 2-9} pea arene |aeeaeeaeger| |e 8 yd weds ss? =n 6nd ods popuouiwosols + (1 ey0.0-6600) WAUL'I—0 1 eB Grid Wa SAS NOUINDL = a ez eas er {DOSED 0) Sear PU Se80H Taye RI = | [eae On AO | = “Toi aoa a 000 98 Nene GO Z| ose vaio a a w Tao 29uE0p IY WRI eG OA ebewen 10) 000 + |_| ! wg 0010 | a ee 2214 10 “a efafe fete tsps |e] wo outa ‘ouibva | wef ve [a [oe | oy | se [be [et [nooo Woneiodo oe oo (aes [ov ous [oe [eae | at | ax omar: souuenwiert 09 | ses gue | oe | see 2 | snuon | —~ ois ows tesiouoipy soy 0 TOW ye Sai | eNO toooza {p.quog) (NOLLIGNOD ONIATHG WON) + F1NGIHOS <“PA8 SCHEDULED MAINTENANCE SERVICES (USA) at e865 Gime OAT « | F 7 Hea. 7 Bevo | FW Sp DOES eve Buy | 1 vend aur gr boi ae 4 ve aw er bonaaeoe fy oso, ‘Gb duu 82 15 sn ve) Sie ZE px eae ve | Baus Hooemee ar | a We vossusues ey Se fo ZEW | (ON TAN) ose ONE wns A yoeday © fe sen _ SBRWRD 1 YOR PE UCI. « 2 eee see arte re Zev 81 5 5 Siu | by Sia uw Sooo obey ; on iad aigate myo F ; cosury ps su : "tera Boa G sc0-a¢9) wine a ins 1 ; uso 90 pie sated m0 von | @98 Sple aaoad 0 Bowe meen ae Wl OF OH) wg 92" wnUIPCE YY eeu maim a roo wun jure | ' (Gea) sae1q wy coup 8 amy tt 2 copa pie te pas 7 ToT auge “unin nae, « £2) wae ae lea Fo ulue oxy“ RURUIY ' ‘Guoy) seveig 261g se 2p eS, + ONS oem me 2 SoLIF HH B10G 3t1 SeINa ; | ee Pee ee « * oe a nai a NEE OS i - Sonsini OTE vn 108 ONY SBSH | [ee | ve | er |amoooie uuojesado oe fee [si | ee mie curser o6eq qiod uopsedsu) pue eyep eojueg oe | zz | sp SL | Suwon 3814) SeUIOD JendyoIYM ‘(S1@}WOU) SoU 40 SYIUOUI Jo 49qUINNY Feasayuy fovea {p.u0D) (NOLLIGNOD ONIAIHG TWWHON) | 37NG3HOSSCHEDULED MAINTENANCE SERVICES (USA) é a : a = nin ag =n Sea a a = ann + sou cas “ByOg PUe syNU Os0o) WE UEWYBNEH pus sug | Gb duy 1 % sn 9 or Val (ib dug") ob sn e ey aay | wane ear ow | a ao anv oT =e eee ee eae Sever oe ee eee eee) on oa eee ‘oo [see | sp | sve sz | s+ | 92 | swwon| a ¥Sayy SOUIGS JORBUOIUM “(GI}EUIOH)) SOU! 10 SyOU JO JOQUINN yensoyuy wooza F (p,qu09) (NOLLIGNOD ONIALHG TWWHON) | FINGaHOS <<SCHEDULED MAINTENANCE SERVICES (USA) = u zed (Aiud oe MGED) ay we OWT = cae Neg 0} Sa Bo Tae SIG + | = TT O50 SOA an EE RTART an = {wos 000'R21) Sonu an0'08 hand eoerloy si {uy 000796) SeINU 000'D9 Alana eoedey a sr a 4 ~ vewcor | —* ; coounp 0)3e8 1 1 1 a Oa TS = |S $ . we lefe fe [epee fe FaRye wa aa ca Porrewn ome. felel[«;slelsle [96 ve | a 8h 9 a oo} ee |e a sr od uopnedeu paw ep or sea | mm pon sip somes | 00 | Bes | or | su ae ss aa suis oN (ONTO sora 1 NOU tum (6 SORIS (P PUR EPEUED 104 pauinbas s1 eoURI ‘]OIYEA BILUO}ED UO PsUIO}ed oq OBIE ¥ FEY} PUBLLIIOOS! OM OAEMOH “Eh ROMO} "PZEW Aq PAPUBUILHODEL ‘Ace! Jeumoz]NUeUI 19 eGe10N09 ALUELEM UOIss|We rk FS ‘*O}IO} ‘NO Sewi0d 1! "S9lU 0Q0'OB PUE SA!LU O90'09 A1ARS TE NO SeWOO CIN) 1UE LoFEO:DU| LORoUNEYY BU ‘seFOIyOA eA “euj6ue 342 0} eBewWep Ul yNsO4 ABU Yoq BulLUN e4y eoe|des o} e1nje (WH 0OO'96) $3) ‘Avon 18 pasinbai 51 yeq Butt ‘slujod Bumojo; 84) @10u ‘yey SoUeUOIUIEW SKA poxew , 30) Sy SIeAJeqU) PepUOUWODAI OY} 1B BOUBUEIUIEW PEqUaSEP ety] Mojo} O| enuTUCD “(4 0O0'96) SAN 000'09 10 SUIYOW Oo JOLY ISMeWO eed ereauany uaiyoi, e6ueyo 40 aoeidoy ‘eoeides 40 UBaj9 ‘yoall09 Avesseoeu y pur “woedsul ssloquiAs weyo, oozza (NOILIGNOD ONIAIG TVWHON) | 37NG3HOS augaxcae A-7SCHEDULED MAINTENANCE SERVICES (USA) Taro mad gona T 5 wea ' ves) soa 280 | e BOLT INS 7 BLOG OSEAN . : site ono «| # ey ng oyeie $a SUORRUCS pe DUR Heel + [1 1 SFR FE BY GOT OR “A008 QNY SISS¥HO Wai raw ED SMUT Joey ROU sa db dun 99 sn 62 sH Se ¥ 4 suep09 au 701504 A 2hyoed9 WOOO» z Tot BOO» sho bio sa oh 10 84009 0 6000H ' \ ! ieee z —WaiSiS BNO [as = a a Pra F711 | oj suauocwoo pue suoo0w09* \ el ee Ci obra i fst (uw (3) wc 020-082 ata (dosnt) fue) gin el wl " wl peed op} sy ws €, 008) 058008 L_ eed 1 nase BE m5 Sa ois om = | T Suu voy | ‘nd prepus, THRE] FSCS = sLnDGOIa | LeSSsuae Truxaoem | S398 108 geo | [stanaoim | .S3suga 5 7 sn 205 siaciowaii| YON snd ds papueunoany + 193-4u1 Bro0—Be0'0) wh"I—o's sopenaseo-(u e650—8e00) wG0 5/0 de Orig « W1SAS NOULNDI ew ale lw Le = oo_[ ees [oe [eve | oe | oar 60a 1d wonoedsu oye = etuietaed oo _| sz sue_|~oc_| sez Say SOUIOD oer *(Srayewor}y) somal ooze F (pauog) (NOLLIGNOD ONIAIHG TWHHON) | 31NGSHOS <<‘SCHEDULED MAINTENANCE SERVICES (USA) [eave are seed TI a BO Huw OL. TESST WAI Trea boqesedo ou) 1580Syp 7ossa1du09) ‘SBE weIsB ye! YOU “Ajahuve junowe jweeBujes ou oda, _ TweRBUTeR 1WALSA8 WBNOLLIONOD Iv = ‘aueeoo wore» [1 i ION TOU WAS nee 7 704 pu SHA 00 LENE» | —L x Tq pie SHAD UO SMU PUP SOR Waurry wenesenes Ty pace | 8 ny vorsueuen oyeuEEY az 1p voceuaven wove TON DIN) 86851 UI AGE 20 peda + ~ ‘ofewep 10) 2849 puP veR!D «| 7 : 1 Sure0q roxy wos ON TIN e580 + | _ Se we wa SayES] IE pur 85010500] SBeUea_« | 1 1 TOIT ET rea uo - > ‘ze pue sp pO! a s[ ' eBoy Buv0.s oN sf 1 BSujsnou 1866 pue suoweado Buvoarg 2i-N ED 1 10 906 Uys peRUEHY ted en (va) soyeig wns [we | a | oe | we | ee | ve oped ees (oy [our {oe [oe | a soueuaiureM a odsuy pus il Bea lod onsedsut pus eiep 2o1N08 eto gu | sk oe Tai soues eho THRISUOTD sop NTONTIC ANN | werowy oozza (P.au09) (NOLLIGNOD DNIAIHG TWWHON) | 37NG3HOS zevgaxon A-9SCHEDULED MAINTENANCE SERVICES (USA) Woiisdo BUD [ =sseeeer ‘Go DOT SzH) SA O0TTTR Alone SartaY 1 WAKO | = a a ri =! gino sdewep, ! te ‘seq eALG aa Weauy ro In seo) Gelseeeatres ean eae fi Ov “ib Sn 8'y) Bm ra wanormmpaneasy fulelel=lelelslslajefuly a ae [oo Toe | ez] v0] 8 | ay | oF we | ve | of | [wnoootx| o3[s5 [05 | ov | oF | se oF | se [oz | sx | oF | = [powoor 09 ss | 0s| sy -or| se [or tse! oz! st] or! s | son 1814) SeWOS serayorym “(Sia}sUIO[Fy) SOI) 40 SUIUOU! JO JoquUINN Be quod uonoedeu pue eiep 6019s “a}O1YOA BIUNOYIED UO PauUOPad aq OBE 1 UL PUBLIWODS OM ‘IeAAMO} “EILIO,}BD Ideoxo SaIRIS [fe Pu! EPEUED 10} paanbsd S| eoUBUETUIEUI SIL. Taumagjnuew 40 a6e!on09 AueLTeM vOSSIIUe 10} A1ess909u JOU | | JOABMOH| “EPZBN Aq PEPUOUIUIODA S| BOVELOIUIEW SL ce ‘SOUBUATUIEW Paquosep ey ‘nOHO} "NO S@WUO9 1 “S3yW 00'0R PUR SajW O00'09 AlBNe 12 NO Seo (7I/N) 1YBN Jo}eOIDU) LONOUNYFEPY YI “SEIOIYOA ‘sjulod Bulmojio} 9uy 8]0u "WeYD BOUPLEIUIEW Syl UL ‘SJPAOTUI papueWUOD! au IB BOUBUE|UIEW PEquOsEp OY) MO} (0) enujucd "(wd 000'96) 88H 000'09 10 SyIOL! Og Jay ssewOY ebueyp 40 808kdoy snip ‘eopxdai 10 Ueef9 “jalloo Aresse00U 1} PUB ‘oad sjoquiks WeUd toosza (NOLLIGNOD SNIARIG ANDINA) Z 31NGAHOS 4SCHEDULED MAINTENANCE SERVICES (USA) Taos 6) SS OOE AS SORT Wiad IO aA OS 0N mae Tae URN : va : iu v0 mM : wo) Soren Uru vend mela | (01) 90 wv 2Bouep 0 at Jo} BUN beyee1 pu voTeedo oUNa OLN © : lea 1 ' ' ' {ucu) sevens cea ea slat 8 ed 1 ci ‘KdO8 ONY SISS¥HO vs 8 8 swe000 auva 7 rai ue «| || a eae ___s20m 10 syo810 19) ses0H1 + | | ! ! meh = : : Wa15AS BW Bimal [Sma Si pw SUS SMT + [7 af sev od ovine = ¥ : = ay auieg | URE SU UE Omar a Hl 7 : zs Wa1SKS Taha ra Day Bia OWE Bult UORNDE Bnd enue, DOE wap | _osnaonoaain z-9 "MZ y 4 rs 7 ae ' sine yds papuauuoey «|| (usioo-sso0 uunimorse8 Sng | | zl i ___| ane zs WELSKS NOUINDI a6 [ou [oa [ez | ve [oe | or [ov | ae [ve | or | 9 [um onix oneiedo : ca oo [se [oe [sy [or [se [oe | sz [0e | st [or | = [swoniix| ~~ _souovewrent Mee bee ea oo [s6 [os] se [or] se [ oe! sz[-oe| si [or] =| son ae dei sowed JOADYOIUM HOVOUI) SONU 1O SLOW HD JERK | yenowu : vwo8ze (P.weg) (NOLLIGNOD ONIAIEG 3NOINN) Z 37NGaHKOS wiSCHEDULED MAINTENANCE SERVICES (USA) aavoaKcia Tat a1 ge a =o eae VOID + een SEingp WeIATIBL OOD + Tanoure aR Bi HOT, a areues Saxe am oT» [| T a TY 7 ‘Or W_| aus bu SERR| ‘SBEwep EUR + | 1 i a Wb Guy eT WEN FZ) su Oe er aoa 4 8 = saa Woe 7 i = OT HUE Siu 6900 r z r Z f (Dai e1 sn 91) 90 ow (ib duy $'t 90 $7 6) 88H 8 u ae ames Psy EE bee bib dun g2 ib sn 0 4 u fo vorseu.sunn fenwony a | base wana v7 vossuuen SyeUN sel [8 u ny vosstueuen ogcIny ZN ela 1 vo 1200 Gunes eruery em : 609 (204 WOH sen ‘beep 10} OND pue wad + | 7 a Buveon oye oH ra zg ZON ITN 280619» | 7 z ae Un ea ou ‘BB@|ee| BGR pu ssouNsoo| ‘Bee « || i TOT roa voRUoETS a lB Bud SUD 60s EN obewep pus sseuaseo, 0} oxi «| | 1 bey BL0as @ GL0-0e 9) unlpe=g ed 9614 = oN Burzoo 10 obeyea| pris = | 1 1 Susro1) 1996 put suoteedo 8wU0es __ssoue600) pue HOHE « | 7KG08 GNV SISSVHO ‘6 [ee [08 | ez | v0 | os | ov | ov | we | ve @ one 09] ss [ 0s | sv | ov | se | ve | se) oz | sp $ ob pedsu 0 a — : wrod wonsedeu pus wrep eames "og | ge [os | sr | ov | se | oc | sz | oz | st $ = ‘WSiiy SauIO9 JOASYOIYM “(SiO}eUIO|F) SONU JO SUIUOU $0 ABqUINN, senso fee 12 {p,1u09) (NOLLIGNOD ONIAIHG ANDINA) Z FINGaHOS <<SCHEDULED MAINTENANCE SERVICES (USA) = I — VORRIOGS OBUD_—« BHR ADS | {Wi 000'S8) Se DONTOD Hore Sowidew Ge ToRIRpRO) ae on HOT = —_ ir n'a217 a4 00108 MS SoeNdoe 3008 vaBS = (Wi 000'98) Sen OOOO Hane SceiGeN [iba Sua = I gi ese asa iuowop sve aN Tail = BeUAp 104 ¥00U 1 7 2 a e I 1 “Tab Ea mst a u wlelelelelala ufele vo waurewenmomre Tulululelslel|e ufele ve e063 = ANE we [oe aL Ware [wre ore ying [08 88089 or [808 si [Or | = jem ori bie eee ee o9 | ss | 0s | sr 08. si for] s | siuoy | 1814 Sew0o Sea eso Saye 40 SYYOW JO seqUINN yearayuy ye9 ideoxe sayeis je pUe epeUED Jo} pouinbo! s| SOUBUAIUIEWISALL by e08) JoanjoeINUeW 40 BBRIENCO AIUENEN UOISSILHE JO} {UBSS8O9U JOU 8! 1901 AeW oq Gun eu aozjdos 01 eunyle (U4 000'96) ‘squiod Bu 2 U| SWB! PSE , 40) Sy ‘SJPMOJU PepUBLUWIODE! B47) JB EOUBUE|UIEUI PAqUOSEP BU} Mojo} O} enuAUCD ‘(WH 000'96) Sell! 00'O9 40 SiLOW a9 JEUY 1S12W9y uB919 "9 e6u2us 10 ooo! (uawieis soueeyo ay" 20eder Aressa0eu # pu "Yoedsu)) eoe|des 40 ueeja “JoaLi09 Aesseoou y) PUB "SdsU “| ssjoquuts euD, oozza (NOLLIGNOS ONIAIUG ANDINN) z F1NGIHOS: -guoxxon, A-13Taro wpe UREN 5 ‘D0 P SSOONL i lea (zo wage unui” | 1 1 (wo) s0y010 26 “Dred 99 10 SsouNoNA é Uopeedo 06D z BOLIP VS 0 G1OO bt SSA ae 7 spy eyeg «| & ¥ pany oe =a SuaqDouNGS poe WeUNHeHE 1edoia + | 1 i ROHSATIGD pw ESOT aT HOE ‘A008 ONY SISSVHO | 2 TRUST 16) SR OOOTE KisKS SOHTSE (Ga ouerd 105) 0 eubv3 4 Woda row sis) suSs g rey mt 2] | ss (ib dus 9'9 wb sn 6) sem SZ 4 4 | yu2jo00 eu 2a4e94 A 8 syed 009 7 TBRaT BION] 0 =} Ls {00 1 81002 10198041 \ warts 6.4009 | & __WAIEAS BNTIOO B) Pea 7 u =] AW ERS Sr en BT LH | oy evoduos pur suomsauuco sums « | | el sour eng z Wy toa) eBver g u wah 067—081 = (un fa) we 022-082 Za Gopineued) aBue) J | gel ol wl wl eds ep} a suv wa @,. 008) 088~008 5 eed’ Oph « ea Z wali Tana | pe GIG aS Gon voRE,_= [T tain vont = ‘ond pueDUeIS, a TimaGeen] Tn -saua a a Surraoim | LSC wwxa02M | $3988 | ornare Bl | zo | |amoaorm| .sseie8 peel u 6nd weds = (OsNGNOdAIN| ON 9 “SOnxd weds pepuauNLccy + a 193-(u: eb0'0—ee0'0) WUT ~'k -oyeingie9-(U) 8600-8200) WwISEO—SL0 do Od + Ts = W1SAS NOLINDI 36 [oe [00 | zz] vo | 95 [ev | ov | a] ve ‘wojts0d0 oof sa tor {sr {or {oe {oe [ee [oe | sh _gounuanuren 28. 7 tured vonsedeu pu sip eames LTE t oe | art oF Lge LO ote Faas Teneton eaneuiony eof 36 MUONS aM | eA < cozza {wo9) (NOLLIGNOD ONIAIEG 3NOINN) Z FINGaHOS <SCHEDULED MAINTENANCE SERVICES (USA) bo 19 : TSSOHIIIES WOOUS+ ‘pce Cor een BERRI WEEE! WOOD» ‘enue wunowe z WLGAS WBNOILIGNOO wiv ‘saremae vowerau [1 |] i I DIS YoY WOIBKS TERPS Eee rE aaa Tia Be SEU UO 8 Wau T sn ei) siow ze Amedeo «| wT | a womse ha 3 wou e ee 7 TON OW O5e00 ua Ade 10 yoedO — eal ‘eB eulep 101 40049 BUE LEIS 2 Sune ON TON "985015 7 ayes we | Sbiye0) 56816 pure ssause09) ‘oDeWeA. 1 Tard saeT 19 wosved I ue pUe SoU Pos ay Cena CineeIs : (© 6£0=02 0) wuuoe=s eis 0614» en Buz00 40 abeye=) pnd [a | | Susnoy 1208 pue suonesedo Buoes s99u9800] pue uowead I i =n | O6SVS FAIEBE TO SOIL Ia HO 7D + ise Giese stat {4 420) wuz (vosueurp tt ' 0 seb uyoors eneyy vere . 1 (ea) sayeig wsucy ‘6eyr0| pure UONEIed HOU UNA + ‘A008 ONY SI 6] 88 [OB aL] vo [ee | a [or] ee ve] or] o [ax oIK co [an fos | sv {ay {ae foe {ae [oe [at [or | fom crt . vuonaad tee ‘wrod vonoadeu pus siep eines 99 T-s5"| og | sr | oF | Se oz] st [orl s | sion ens Soi teuoTON Telenor vo USN |S SOQ | ese) oozea {pauoa) (NOLLIGNOD ONIATHG SNDINN) Z 71NGIHOS zquomo A-15é it tif A SCHEDULED MAINTENANCE SERVICES (CANADA) t | if Taintonance Tanta’ of months oF wiles (Wlomete), whichever comes At i interval |—~Wontne [8 [10 | 18 | 20 | 28 | 20 | 38 | a0 ao sr00 ke |e 16 [a | oa | ao | a8 | 80 | oe | Litem («1,000 miles) | (6)_| (10) | (18) | (20) | (2s) | (30) | (38) | (40) | (45) | (50) | (65) | ENGINE k | [Engine al ADR TATA TALE © | [outiter RODR PR DAR | A Tension ofa Give Dats Ce Engine ining bets FOR 220077 z | AIR CLEANER |) [iter coment Ie or Fees eee een] IGNITION SYSTEM [Spark plugs eee tr [ee etsn fevers eesti eevee seas eee COOLING SYSTEM ‘Engine Gosia ove) and srengih ie-ene[er ieeletealeatafaaT | [feeoina evstor for fears i 1 i 1 | Engine cociant Tea) a E FUEL SYSTEM Tele speed Ty 7 Fuel ines and Fees Fue) for Choke sysamn FOR GARE c c 3 Tas sich FOR OAR, 1 i POW valve = HAC a iter FOR GARB. ‘Emasion hess and UDSE : EGR vavo FOR GARB C Oxygen sensor : Tepane every 128,000 Kamera CHASSIS & BODY | [Rfomatic wanamssion Tid vel i oO | [Transmission of MrT and ArT [Oi lvel in inal orive and warsiereass |]. 11 [a {1 madels 80 eauipoed) Diferonta! oll Transfer ca52 Oi FOR ANA Propoie’ shal (FOR 4a) t ‘Dive shalt dus boat (FOR 4x4), ‘Brake fnos ang noses i | [Brake and ciuioh fuid ve oe Brake fio Diss brakes i Fear drum brakes Front whos bearings “re ifaion pressute Sha We Var a ovale tres i Fojats aveiy 24000 5 | Manual stoonng Gear Gi ivel I Power org Mud vol a ‘Steering operation and inkage {incudes four whee alignment) Slowing gear Rousing for freeplay and i 7 efor | ‘Suspension Components WORE ana rear lesa 1 g\s/8 ) | —|-2] 2) i i j 1 i i i A-16SCHEDULED MAINTENANCE SERVICES (CANADA) A Waintenance Number of months or miles (Kilometer), whichever comes first Interval | ~“Months 5 [10 | 15 | 20 | 25 | a0 | 35 | 40 | 45 | 50 | 85 | 60 a 4,000 km [8 | 16 | a4 | 32 | 40 | 48 | 66 | 64 | 72 | 80 | 83 | 96 Item (1,000 mites) | ¢) | ¢10) | (18) | (20) | (26) | «20) | (25) | (40) | (45) | (50) | (65) | (60) CHASSIS & BODY Upper arm shafts c T ‘All chassis and body nuls and bolts T T T Exhaust system heat shield 1 All locks and hinges et seis eiLee [eora seles [estore Cpe ye ‘Washer fuid level A TPTre Function of all ighié A AIR CONDITIONER SYSTEM (IF EQUIPPED) Retfigerant Tnspect the refigerant amount annually z “Compressor Inspect the operation annually Note Inspect, and if necessary correct, clean or replace. (Inspect, and if necessary replace...Air cleaner element 2200 only) R: Replace or change T: Tighten L! Lubricate Clean Aiter 60 months or 96,000 km (60,000 miles), continue to follow the described maintenance items and inter- vals periodically ‘As for *marked items in this maintenance chart, pleace pay attention to the following points. "1: Replacement of the timing belt is required at every 96,000 km (60,000 miles) Failure to replace the timing belt may result in damage to the engine. * 2: This maintenance operation is recommended by Mazda, However, this maintenance is not neces- sary for emission warranty coverage or manufacturer recall lability *3: The Maltunction Indicator Light (MIL) comes ON at every 96,000 km and 128,000 km, If it comes ON, foliow the described maintenance. PauonoisENGINE (B2200) TROUBLESHOOTING GUIDE .. ENGINE TUNE-UP PROCEDURE DRIVE BELT. HLA TROUBLESHOOTING GUIDE . COMPRESSION COMPRESSION .. ON-VEHICLE MAINTENANCE. TIMING BELT wessseu CYLINDER HEAD GASKET .. FRONT OIL SEAL. REAR OIL SEAL. REMOVAL .... PREPARATI ENGINE STAND INSTALLATION. PREPARATION INSTALLATION DISASSEMBLY. PREPARATION. AUXILIARY PARTS .. TIMING BELT CYLINDER HEAD. CYLINDER BLOCK CYLINDER BLOCK INSPECTION AND REI PREPARATION ASSEMBLY. PREPARATION... CYLINDER BLOCK T.... CYLINDER BLOCK IT CYLINDER HEAD. TIMING BELT AUXILIARY PARTS ENGINE STAND REMOVAL .. REMOVAL... INSTALLATION, PREPARATION B1| B1 INDEX INDEX \ ~ i Goes Caouennies 1 mpethcnc pace Bes ve cowpneseion Wee] SOME N ae 10 We} STANDARD; 1,197 KPa (12.2 kglem’, 173 psi300 rpm L eee etre aati : RAS Ay 2-02 EET ey de : a it i a FRSINE boon INSPECTION, SEONEESSRENN ® — exene on nsrecron, | SSN SeOCRTD ORVE BELT ADJUSTING, PAGE BI=S DEFLECTION a cave aT a =) | ERO —| wees RET) | woo saw || 1 a ‘AIG COMPRESSOR | 10.0—12.0 (0.99--0.47) | 120—14.0 (0.47055) — | 1. engine 2.Timing belt | Removal page 81-20 TEOMA wusseencennenncnsnnn POD BI 8 : Bieaesoribiy page B1-24 instalation fege BI10 he Inspection and Repair ee page B1-34 Inspection sesssssessssareney PAGE BI-A4 } P a i Assembly....... page B1-46 3. Cylinder head gasket i Installation age 61-69 Romovel snsnnemsnee page 61-18 instalation page BI1-15 Bi-2 SeOUTLINE, TROUBLESHOOTING GUIDE Bi OUTLINE SPECIFICATIONS: == Es a en aa i [ie in Fa a aay ota i ofa eared cone wp J ‘ies Sie tain [Banaras aaa Ba Gg Soon ae SMO cabasat eaze ee Tea —— = Gun BS = | oe Close ABDC Ea aaa lex Open BBDC 58° rear — se ie ry iN mm (ny 0; Maintenance free ra aeeee xX mmm (in) 0; Maintenance free — ver a a wae ise [Pm [AIT range) 30028 770 20 zt a TROUBLESHOOTING GUIDE Problem | Possible Cause Remedy Page Dita ering | Wainstn a one ra combo Bas reo ss Sa an eo oe Bae [aes eine es Bs Nseon ol aon par nF Msarton festa sien fb for rg Hefner of nested onsen iter ees ep Mee tet cot Become | BH ra Sr na fs a | anette fie 6 SOF li slong st Faro Sea Scene ad ——] bron Seamct | SUNTETETE acne erste oon emo | Rca sie DBS ee REE | ofete wong own Sexes sie av Mi eh ase ies a Oi sap Fa an B1-3: TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page TInsutficient power | insufficient compression Malfunction of HLA Replace e140 CComoression Isakage from valve seat Repair BI27 Seized valvo stem Foplace 51-35 ‘Weak o° broken valve spring Ropiace 51-38 Faies eyindor head gacket Replace 81-13 Cracked or distorted cylinder head Replace Bias Sfcking, damaged, of worn piston ring Replace Bie Cracked of worn piston Replace Bie [Matfunction of fuel system Reter fo Sections Ft, F2 Malfunction of ignition system Reler ta Section G ‘Others Sipping clutch Reler ta Section Dragging brakes eter to Section P Wrong siz fires Fate: to Section O ‘Abnormal Malfunction of engine-related components ‘eombustion Malfunction of HLA Replace B40 Steking or burned valve Replace 81-35 ‘Weak or broken valve spring Replace 1-38 ‘Carbon secumulaion in combustion chamber Eliminate carbon = Maitunction of fuel system Fler to Sections FY, F2 Malfunction of ignition system lar to Section G Engine noise ‘Crankshaft oF bearing related parts Excessive main bearing oll clearance Replace or repair Bi-a9 Main bearing seized or heat-damaged Replace Bias Excessive crankshait end play Replace or repair 1-50 Exceceve connecting rod beeting al clearance Replace or repait Bist Gonnscting rod boating seized or heat-damaged Repiace Bias iston-related parts Worn eyinger Foplaco oF repair Bio Wom piston oF piston pin Replace Bis Seized piston Replace Bia Damaged piston ting Replace B14 Bent connecting rod Replace a1-43 Valves of timing-related parte Malfunction of HLA" Replace BI-40 Broken valve spring Replace Bi-33 Excessive valve guide clearance Repiace I-35 Insufciet Movication of rocker arm Repiace 8140 Malfunction of cooling system ater to Section E ‘Malfunction of fuel system Fifer to Sections F1, F2 Others Malfunction of water pump bearing Refer to Section E Improper dtve-belt tension Adjust Bis Mattunction of alternator bearing | Refer to Section G Exhaust gas leakage Fifer to Sections Ft, F2 Maltunetion of timing belt tensioner Replace Bin 8 od = Tappet noige may occur the engine is not operated for an extended period. The noise shoud disappear ater the engine has reached normal operating temperaire. Bi-4 featsENGINE TUNE-UP PROCEDURE B1 ENGINE TUNE-UP PROCEDURE DRIVE BELT 1. Check the drive bells for wear, cracks, or fraying; replace if necessary. 2, Check the drive belt deflection by applying moderate pres- sure (98 N, 10 kg, 22 1b) midway between the pulleys shown in the figure. Adjust if necessary aaa Deflection mm (i ‘PrS OWL PUMP: ADJUSTING BOLT ao Dave bet New eet | ane lees 88 _(028-031) (031-035) 70-80 30-90 P98 ol pump 025-031) (031025 os 700-720 720140 AIG comoresio 29-047) (047058) 3. Check the drive belt tension with the tension gauge, . Note ee aera cot Belt tension can be measured among any pulleys. \ Mest No.) Dive bat New T Used 31580 320-481 | Aerator ose tociey | ao sabe t110) 2s—294 198-25 mounma 80uT PIS of pump (25-20, 55-05) | 20-25, 4455) 441540 348 —aat ‘AVC compressor cama (ass, 99-129 | @5—95, 77-29) Adjustment (1) Alternator belt lf necessary, loosen the aiternator bolts and adjust the belt deflection, Tightening torque Bolt A: 31—46 Nm (3.2—4.7 m-kg, 23-34 ft-lb) Bolt B: 3752 Nm (3.8—5.3 m-kg, 27—38 ft-lb) (2) PIS oil pump belt lf necessary, loosen the locknut and adjust the bett deflection by turning the adjusting bot Tightening torqu 37-52 Nm (3.8—5.3 m4 27—38 ft-lb) Bi-5HLA TROUBLESHOOTING GUIDE ENGINE TUNE-UP: PROCEDURE, COMPRESSION | (8) AIC compressor bett If necessary, loosen the mounting bolts and adjust the bbelt defiection by turning the adjusting bot. Tightening torque: ‘37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb) 2 5 Problem Possible Cause ‘ion |]. [temo wen oname s sed Hamedaay [Ol eatage nol) Fin angie wt 20005000 ron is | Getot's chanaes passage Foe slope after 2 sacord—10 minutes’, HLA s A | 2, Nose unten engine i tated after seting formal APG LE. aprox one ay. Wek replace HLA Lo. [Nese when encira is sarod afer cank- | Ol eakageir” | Tyme requied for enging oo cree TPee Te eee neato re me {it ncuvos tera for engine of conten ard 1 4, Noise when engine is started after new ambient temperature. Aas [2 NtA‘sineated 3 Hows contmucs more fan 10 minutes | (reuicant of | Check a pressure. (ler Secton 0) pressure Ilower then specication, Shock fr cause Oli pressure; 304—402 KPa (G14. kgfer, 44—58 ps!)-3000 rpm Fauly WA] (Raa to pane 82-69) Pree down fecker art by hand ihe moves, place HLA {Ft ases not move, HLA nora ‘Meanie vave sosrance. tinove than Bram (0) replace HLA 3. Nal casas danny Wo aor Fgh opeed | Wcorec Gt | Check of Fal runing amour Bran of ed ol as neces Bateraior oF | Check ot quality W Seer. ace wn sects yp ad aro oot Tar Tnoearor COMPRESSION tt the engine exhibits iow power, poor fuel economy, or poor idle, check the following: 1. Ignition system (Refer to Section G.) 2. Compression 3. Fuel system (Refer to Sections F1, F2.) COMPRESSION 1. Check that the battery is fully charged. Recharge it if necessary, 2. Warm up the engine to the normal operating temperature. 3. Tum it off for about 10 minutes to allow the exhaust mani: fold to cool. 4, Remove all spark plugs. 5, Disconnect the primary wire connector from the ignition coil ,COMPRESSION B1 6. Connect a compression gauge to the No.1 spark plug hole, 7. Fully depress the accelerator pedal and crank the engine, 8. Note the maximum gauge reading. 9. Check each cylinder. Compression: 1,197 kPa (12.2 kg/em?, 173 psi)-300 rpm Minimum: a 834 kPa (8.5 kg/cm’, 121 psi)-300 rpm ty SaTORT Possible Cause i.compression i iow, pour heavy a int tho onder and tun fe erankshait sovra mes i hack compression ance more I Is compression increased? 1, Wor piston ot piston rings 2 Worn eyinder wi 1. Delecive oyinder head gasket No 2 Boned Sno head | eS ves : : Ts canpesson in aden der? no 1 tapope sao wong | 2 Wipe Si guce 3. Defective cyinder head gasket wae B1-7| Bi ON-VEHICLE MAINTENANCE (TIMING BELT) ||| ON-VEHICLE MAINTENANCE TIMING BELT |, Removal 1. Disconnect the negative battery cable. | 2. Drain the engine coolant |. 3. Remove in the order shown in the figure referring to the Removal note, TSO <4) 1.Cooling fan 7, Crankshaft pulley 2 Radiator cowiing 8. Timing belt cover upper 8. Alternator drive belt 9. Timing belt cover lower 4, Cooling fan pulley 40. Timing belt tensioner and spring 5. Cooling fan bracket 11. Timing belt 6. Secondary air pipe assembly (Carburetor) Bi-8ON-VEHICLE MAINTENANCE (TIMING BELT) Bi DIRECTION ARROW Removal note Timing belt tensioner 1. Tum the crankshaft to align the $1 mark of the camshaft pulley with the front housing matching mark 2, Remove the tensioner and spring, Timing belt Mark the timing belt rotation for proper reinstallation if itis reused. Caution Be careful not to allow oil, grease, or water on the belt. Inspection Inspection of timing belt related parts. (Refer to page B1-44,) seunero%e B1-9ON-VEHICLE MAINTENANCE (TIMING BELT) Installation Install in the reverse order of removal referring to the Installation note. oe Caution After radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. If the fan touches the cowling, adjust the radiator cowling mounting position. Note a)Position the hose clamp in the original location on the hose. b)Squeeze the clamp lightly with large pliers to ensure a good fit. if |, Torque Specifications b I | onan (7O=100 cart, 6187 i) (as 73, 9-19) en ook mb) TBUOBI CTS B1-10aa ON-VEHICLE MAINTENANCE (TIMING BELT) Bi Installation note Timing belt 1. Check that the mark on the timing belt pulley is aligned with the matching mark. 2. Check that the #11 mark of the camshaft pulley is aligned with the matching mark. If tis not aligned, turn the came shatt to align, 8. Install the timing belt tensioner and spring. Temporarily se- ‘cure it with the spring fully extended, 4. Install the timing belt so that there is no looseness at the water pump pulley and idler pulley side. Caution 9) if the timing belt is being reused, it must be rein- stalled to rotate in the original direction. b) Check that there is no oil, grease, or dirt on the tim- ing belt. Note Remove all spark plugs for easier rotation. 5. Tum the crankshatt twice clockwise in the direction of ro- tation. 6. Check that the matching marks are correctly aligned. If not, repeat the above-mentioned procedure. 7. Loosen the tensioner lock bolt and apply tension to the belt Bi-11nea B1-12 ON-VEHICLE MAINTENANCE (TIMING BELT) 8, Tighten the timing belt tensioner lock bot. Tightening torque: 37—52 Nan (3.8—5.3 m4 27-38 ft-lb) 9, Turn the crankshaft twice in the direction of rotation and align the matching marks. 10. Check the timing belt deflection, If the deftection is not cor- rect, repeat the adjustment from step § above, Timing belt deflection/98 N (10 kg, 22 Ib) New : 8.0—8.0mm (0.31—0.35 in) Used: 8.0—10.0mm (0.35—0.39 in) Caution Be sure not to apply tension other than that of the ten- sloner spring. Spark plug 1. Install the spark plugs Tightening torque: 15—23 Nm (1.5—2.3 m , 11-17 ftlb) Steps After Installation 1. Adjust the drive belt tension. (Refer to page B1-5.) 2. Add engine coolant to the specified levels. 3. Connect the negative battery cable. 4, Start the engine and do the following: (1) Check for leakage of engine coolant. (2) Perform engine adjustments if necessary. (8) Recheck the coolant leveis. souosroreON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) Bi CYLINDER HEAD GASKET Removal Warning: Release the fuel pressure. (Refer to Sections F1, F2.) 1, Disconnect the negative battery cable, 2. Remove the engine undercover. 3. Drain the engine coolant. 4, Remove in the order shown in the figure referring to the Removal note (CARQURETOR ® 1. Air cleaner assembly (Carburetor) 2. Air intake hose (EG) 3. Cooling fan.and radiator cowiing 4, Accelerator cable 5. Fuel hoses 6. Fuel pump (Carburetor M/T) 7. Heater hoses 8. Brake vacuum hose 9. Three-way solenoid valve assembly 10. Duty solenoid valve assembly 11. Canister hoses 12, Engine harriess 18. High-tension leads and spark plugs 14. Distributor Ser, | REPLACE, Eo 18. Secondary air pipe assembly (Carburetor) 16. Radiator hose, upper 17. Water by-pass hose 18. Intake manifold assembly 19, Exhaust manifold insulator 20. Exhaust manifold 21. Timing bett cover, upper 22. Timing belt tensioner and spring 23, Timing belt 24. Engine ground 25. Cylinder head cover 26. Cylinder head bolt 27. Cylinder head 28, Cylinder head gasket B1-13B1 ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) [GARQURETOR a @. © @ g TORT Removal note Fuel hose Note a) Cover the hose with a rag because fuel will spray out when disconnecting. b)Keep sparks and open flame away from the fuel area. Plug the disconnected hoses to avoid {uel leakage. Timing belt 1. Before removing the timing bett, turn the orankshaftto align the 41 mark of the camshaft pulley with the front housing matching mark. 2, Loosen the timing belt tensioner lock bolt 3, Shit the tensioner outward as far 2s possible, then temporer- ily tighten it 4, Remove the timing bet and secure it out of the way to pre- vent damage during removal and instalation of the cylin- der heed. Cylinder head bolt Loosen the cylinder head bolts in two or three steps in the order shown in the figure.ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B1 ] Disassembly of Cylinder Head | Refer to page B1-28. Inspection of Cylinder Head Refer to page 81-34, Assembly of Cylinder Head Reter to page B1~56. wea Installation Install in the reverse order of removal referring to the Installation note. Caution Alter radiator cowling installation, rotate the cooling fan by hand and verify that the fan blade does not touch the radiator cowling. If the fan touches the cowling, adjust the radiator cowling mounting position. Note a) Position the hose clamp in the original location on the hose. b)Squeeze the clamp lightly with large pliers to ensure a good fit. Torque Specifications (20110 crag, 6525 in) 12s (18F6, 419)Bi ON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) Installation note | Cylinder head | 1 Thoroughiy remove all dir and oi from the top of the eylin- ax der block with a rag. 2, Place a new cylinder head gasket in postion. 3. Set the cylinder head in place. 4. Apply engine oll to the bolt threads and seat faces, 5, Tighten the cylinder head bolts in two or three steps in the order shown in the figure, Tightening torque: '80—B6 Nm (8.2. .8 m-kg, 59—64 ft-b) Cylinder head cover +1. Apply engine oll ta the valves and rocker arms. 2 Apply silicone sealant to the shaded areas shown in the figure 3. Install the cylinder head cover. aes Tightening torque: 2.93.9 Nim (30—40 cm-kg, 26—36 in-lb) mae Timing belt + Align the 441 mark ofthe camshaft pulley with the front hous: 19 matching mark 2. Install the timing bet. (Refer to page B1-10.) Distributor 4. Apply engine cil to the new O-ring, and position it on the distributor. 2. Apply engine oll to the distributor driven gear. 3. Align the distributor housing and driven gear marks. 4, Install the distributor into the front housing, 5, Loosely tighten the distributor mounting bolt. oe ERTSON-VEHICLE MAINTENANCE (CYLINDER HEAD GASKET) B1 DST Spark plug 1. Apply ant-seize compound or molybdenum-based lubricant to the spark piug threads, 2. Install the spark plugs, Tightening torque: 15—23 Nem (1.52.3 m-kg, 11—17 ft-lb) Steps After Installation 1. Add engine coolant to the specified levels. 2. Connect the negative battery cable 3, Start the engine and do the following: (1) Check for leakage ot engine coolant (2) Perform engine adjustments if necessary. {@) Recheck the oil and coolant levels sezose B1-17Bi ON-VEHICLE MAINTENANCE (FRONT OIL SEAL) FRONT OIL SEAL |p. Preparation ssT 495120710 so 4011 101A ®) 4 | Holder, couping == | crankshatiock wed | ange tool # eam 4 aE TS Removal 1. Disconnect the negative battery cable. 2. Drain the engine ol. 3. Remove the timing belt. (Refer to page B18.) 4 Remove the timing belt pulley with the SST. 5. Remove the oil seal with @ screwdriver and a rag. Installation Install in the reverse order of removal referring to the instal lation note. Installation note Front oll seal +. Apply engine oil to the new seal lip. 2 Fit the oil seal onto the oll pump body. 8, Tap the oil seal in evenly using a suitable pipe. il seal outer diameter: 48mm (1.89 in) Caution The oil seal must be tapped in until itis flush with the edge of the oil pump body. Timing belt pulley Install the timing bett pulley with the SST. Tightening torque: 457—167 Nem (16.0—17.0 m-kg, 116-128 ft-lb) ‘Steps After Installation +. Add engine oil to the specified levels. 2.Connect the negative battery cable. 8 Start the engine and do the following: (1) Check for leakage of engine oil {2) Perform engine adjustments if necessary. {@) Recheck the oil levets. wearsON-VEHICLE MAINTENANCE (REAR OIL SEAL) B1 REAR OIL SEAL Preparation sst 49 E011 140 49 SE01 910 Ring gear brake " Clutch aise sel centering took BaD Bare Removal 1. Disconnect the negative battery cable. 2. Drain the engine oil ‘8. Remove the manual transmission, (Refer to Sections J1, J2, J3,) Remove the automatic transmission. (Refer to Sections K1, K2, K3.) 4. Remove the cluich cover, clutch dise, and flywheel with the SST. (Refer to Section H.) Remove the plate, drive plate, and adapter with the SST. (Refer to Sections Ki, K2, KS.) 5, Remove the oil seal with a screwdriver and a rag. Installation Install in the reverse order of removal reterting to the Installation note. Installation note Rear oil seal 1. Apply engine oil to the new oil seal lip. 2. Fit the oil seal onto the rear cover. 8, Tap the oil seal in evenly using a suitable pipe. Oil seal outer diameter: 140mm (4.33 in) Caution The oll seal must be tapped in until it is flush with the i edge of the rear cover, Steps After Installation 1. Add engine oil to the spectied levels 2. Connect the negative battery cable. 8. Start the engine and do the following: (1) Check for leakage of engine cil (2) Perform engine adjustments if necessary. (3) Recheck the oil levels, xno Bi-19B1 REMOVAL | |REMOVAL | | PREPARATION [| osst 49 wo2a 5054 ‘dus wronch — waa § | Warning: Release the fuel pressure. (Refer to Sections Ft, F2.) 1 | 4. Disconnect the negative battery cable. £ | 2, Remove the starter (Refer to Section G) and transmission. (Refer to Sections J1 U2, J3 and K1, K2, K3.) 3, Drain the engine oil and coolant. | 4. Remove in the order shown in the figure referring to the Removal note. | BI-201. Air cleaner assembly 2. Cooling fan and radiator cowling 3. Accelerator cable 4. Fuel hoses 5. Heater hoses 6. Brake vacuum hose 7. Three-way solenoid valve assembly 8. Vacuum solenoid valve assembly 9. Canister hoses 10. Engine harness [eARBURETOR Taso REMOVAL B1 11. Engine ground 12. Secondary air pipe assembly (Carburetor) 13, Radiator hoses 14. Radiator 15. Binaust pice 18. A/C compressor 17. PIS oil pump pulley 18. P/S oil pump 419. Engine mount ruts mento Removal note Fuel hose Warning 2) Cover the hose with a rag because fuel will spray ‘out when disconnecting. '»)Keep sparks and open flame away from the fuel area, Plug the disconnected hoses to avoid fuel leakage. P/S oil pump pulley Remove the PIS oil pump pulley with the SST. P/S oll pump, A/C compressor Remove the PIS oll pump and A/C compressor with the hoses stil connected to them; secure the pump and compressor as shown in the figure. Bi-21: Bi ENGINE STAND INSTALLATION [ENGINE STAND INSTALLATION REPARATION sst i 1 1] ss o1or ea ev TTD pg | eiterm 1 | env sana ang ge ) pa E sand Be | Por ot E Le |stoow * Lt oaee ae Pra i = Hee) ote zee 6 1 | eta Utes We E 49 LO10 140) 49 LO10 1A0) 49 LO10 1A0) ie : maar IPE | to10 108 Q | evo 08 TEE | oot = |i Sts oa Le | 8tiou0 sto v0 iH i}; INSTALLATION | |) 1, Remove the parts in the order shown in the figure. { } 2 Install the engine to the engine stand referring to the Installation Note. He + Ht | Hee | i eager, serve | | | | » l eee oS 1. Exhaust manifold insulator 4.01 vel gauge 2. Exhaust manifold 5. AIC compressor and P/S oil pump bracket 3 Engine mounts Bi-22ENGINE STAND INSTALLATION B1 Installation note Engine Hanger 1. Install the SST (arms) io the block holes as shown in the figure and loosely tighten SST (bolts A). 2. Assemble the SST (bolts, nuts, hooks and plate). 3. Install the SST assembly to the respective arms while ad- justing parallelism between the arms and plate by turning the bolts and nuts. Warning Use special caution while turning the engine stand handle to prevent hand injury. 4 Tighten the bolts and nuts to fix the SST. 2 5. Install the engine on the SST. FOE "ao Bi-23|, Bi DISASSEMBLY 4} | DISASSEMBLY q PREPARATION Sst Po [ae e011 140 49 0698 1004 49 G090 202 pe é te Seng er i 49 1285 O71 49 L011 OAD & 49 L011 001 ! WE SB) | Pater, bearing menif}—eres | Psion pin sting S} | suppor block | toa ea g mo RSS | Gala : Slot on 1 | | 49 vo1t 008 wrioroo 49 Lott 006 1 | seen ace Se io P| hose Canet tare 11) | ean ot ‘49 L011 0A0) 49 LO11 AO) © [SSS ono | il i || | 49011 008 49 Lott 010 | 49 tors on £ | aude a Centering tool Holder ono patel A jean 8 ~ £ [Ssh ono {Lott 010 $e Lots 010) aT 4, Code all identical parts (such as pistons, piston rings, connectings rads, and valve springs) so that they can be reinstalled in the cylinder from which they were removed 2. Clean the parts with steam; blow off any remaining water with compressed air. Note During the disassembly of any part or system, be sure to study ts order of assembly. Also, note any deformation, wear, or damage. smonzor? § g 1 RX 2DISASSEMBLY (AUXILIARY PARTS) B1 AUXILIARY PARTS Remove in the order shown in the figure. ‘CARBURETOR Ten 4. Distributor and high-tension leads 8. Alternator 2. Spark plugs 9. Alternator bracket and cooling fan bracket 3. Rear engine hanger 10. Fuel pump (Carburetor M/T) 4. Front engine hanger 11. Oi fiter 5, Thermostat cover 12. Oil pressure switch 6. Thermostat 13. Coolant bypass pipe Service ... Section E 14. Coolant inlet pipe 7. Intake maniiold assembly Bi-25; B1 DISASSEMBLY (TIMING BELT) TIMING BELT || |) 1. Remove in the order shown in the figure referring to the Disassembly note, oe i el {|} Inspect all parts and repair or replace as necessary. ; ieeenesae % \ va | - TRE 6. Timing belt idier pulley 7. Timing belt aan 8. Camshaft pulley 9. Timing belt pulley 1, Crankshaft pulley 2. Upper timing belt cover 3. Lower timing belt cover 4 Baffle plate 5. Timing bett tensioner and spring B1-26DISASSEMBLY (TIMING BELT) B1 TRI Tan Disassembly note Crankshaft pulley 1. Set the SST against the flywheel 2. Remo the crankshatt pulley. Timing belt 1. Looser the tensioner lock belt, and remove the tensioner spring, 2. Mark the timing belt rotation for proper reinstallation fis reused! 3. Removp the timing belt Cautic Be careful not to allow oll or grease on the belt. Camshaft pulley Remove the pulley lock bott using a screw driver to prevent the camshatt from turning, Timing belt pulley Remove he timing belt pulley with the SST. B1-27er | | Bi DISASSEMBLY (CYLINDER HEAD) CYLINDER HEAD 1. Remove in the order shown in the figure referring to the Disassembly note. 2. Inspect all parts and repair or replace as necessary. = 6 vawve sea, oa EE ®, SEAL CAP, REPLACE. 1. Cylinder head cover and gasket 9. Cylinder head gasket 2. Front housing 10. Valve keepers 3. Rocker arm and shatt assembly 11. Upper spring seat Inspection page 81-40 12. Valve spring, outer and inner 4. Hydraulic lash adjuster (HLA) Inspection : page B1-38 Inspection page B1-40 13, Lower spring seat 5. Seal cap 14. Valve 6. Camshaft Inspection... . page B1-35 Inspection nen page B1-39 18, Valve seal 7. Cylinder head bot Inspect for wear or damage 8 Cylinder head 16. Valve guide INSPOCtiON no page 81-34 inspection page B1-35 Replaceme: page 81-36 B1-28DISASSEMBLY (CYLINDER HEAD) B1 Disassembly note During disassembly, inspect the following. 1, Camshaft end play (Refer to page B1-40.) 2. Camshaft journal oil clearance (Refer to page 81-39.) Rocker arm and shaft assembly +. Loosen the bolts in two or three steps in the order shown in the figure. 2. Remove the rocker arm and shaft assembly together with the bolts. Caution ‘Do not mix up the parts of the rocker arm and shaft assembly. Hydraulic lash adjuster (HLA) Removethe HLA by hand. I this is diffcul, remiove it with pliers | Caution Do not remove the HLA unless necessary because oll leakage will occur if the O-ring Is damaged. hp aaa? Cylinder head bolt Loosen the cylinder head bolts in two or three steps in the order shown in the figure, a = Valve Remove the valves from the cylinder head with the SST. B1—29B1 DISASSEMBLY (CYLINDER BLOCK) CYLINDER BLOCK I 1, Remove in the order shown in the figure referring to the Disassembly note. 2. Inspect all parts and repair or replace as necessary. (GASKET. REPLACE GasKer, REPLACE 1. Clutch cover (MD, Backing plate (AT) 2. Clutch disc (MM), Drive plate (A/T) 3. Flywheel (M/), Adapter (A/T) 4. End piate 5.Oll pan Inspect tor damage ETS 6. Oil strainer 7. Stiffener 8. Rear cover 8. Water pump assembly Service Section 10. Oil pump assembly Service... Section D Disassembly note Clutch cover, flywheel (M/T) or drive plate (A/T) Remove the ciutch cover and flywheel (MIT), or drive plate (A/D) with the SST.DISASSEMBLY (CYLINDER BLOCK) B1 CYLINDER BLOCK II 1. Remove in the order shown in the figure referring to Disassembly note. 2. Inspect all parts and repair or replace as necessary, a sure 4. Connecting rod cap 5, Main bearing cap 2. Connecting rod bearing 6. Crankshatt Inspect for peeling, scoring, or damage Inspection page 81-43 8. Conneeting 10d, piston and piston pin Inspection pages B1—42, 43 4, Piston ring Inspection... neneeeenee PAGS BI~42 7. Pilot bearing (MT) 8. Main beating Inspect for peeling, scoring, or damage 9, Cylinder block Inspection... page B1~40 Bi-31DISASSEMBLY (CYLINDER BLOCK) Disassembly note Connecting rod and cap Before removing the connecting rod, clean the bearing, con- ee necting rod, and crankpin, and measure the following: 1. Connecting rod side clearance (Refer to page 81-51.) 2. Crankpin oil clearance (Refer to page B1-51.) Main bearing cap Before removing the main bearing caps, clean the bearings, main journals, and caps, and measure the following points. 1. Crankshaft end play (Refer to page 81~50.) 2. Main journal oil clearance (Refer to page B1—49,) Pilot bearing (M/T) 1. Before removing the pilot bearing, inspect for sticks or ex cessive resistance by turing the bearing while applying force in the axial direction, 2, Remove the pilot bearing from the crankshatt with the SST if necessary. Note When replacing and/or cleaning the crankshaft, re- move the pilot bearing. aaa Piston and connecting rod 1, Before disassembling the piston and connecting rod, check the oscillation torque as shown, Ifthe large end does not drop by its own weight, replace the piston or the piston pin. 2. Assemble the SST as shown ich—_——DISASSEMBLY (CYLINDER BLOCK) Bi ———— _ 3 Insert the SST No.2 into the piston pin as shown and fully Nee sorew in the SST No.1. oa | | \ = in Ce Ey 4, Mount the piston and connecting rod in the SST as shown. 5, Press out the piston pin. While removing the piston pin, check the pressure. if itis lower than 4,905 N (500 kg, 1,100 Ib), replace the piston ppin or connecting rod. Bi-33,B1 INSPECTION AND REPAIR || INSPECTION AND REPAIR PREPARATION sst 49 0221 2514 so L012 040 BE | «91012 002 jomiover | Instafer set, valve, Ir Nt 0) cane tao y) 49 L012 AO) 49 LO12 040) 1. Clean all parts, being sure to remove any gasket fragments, dir, oil or grease, carbon, moisture residue, or other foreign materials, || 2. Inspection and repairs must be performed in the order specified. Caution Do not damage the joints or friction surfaces of aluminum alloy components (such as the cylin- der head or pistons). Cylinder Head 1. Inspect the cylinder head for damage, cracks, and leakage of water or oi. Replace if necessary. 2 Measure the cylinder head distortion in the six directions shown in the figure. Distortion: 0.15mm (0.006 in) max. 3. Ifthe cylinder head distortion exceeds specification, grind the oylinder head surface lithe cylinder head height is not within specification, replace a Height: 91.95—92.05mm (3.620—3.624 in) Grinding: 0.20mm (0.008 in) max. Note Before grinding the cylinder head, first check the fol- towing. Replace if necessary. * Sinking of valve seat ‘* Damage of manifold contact surtace © Camshaft oil clearance and end play sasINSPECTION AND REPAIR B1 | wana THICKNESS VALVE FACE I ANGLE ase eu Enon VALVE GUIbE VALVE STEM 4. Measure the manifold contact surface distortion in the six directions shown in the figure. Distortion: 0.15mm (0.006 in) max. 5. If distortion exceeds specification, grind the surface or re place the cylinder head. Valve and Valve Guide 1. Inspect each valve for the following. Replace or resurface if necessary. (1) Damaged or bent stem (2) Roughness or damage to face (3) Damage or uneven wear of stem tip 2.Check the valve head margin thickness. Replace if necessary. 1.5mm (0.020 in) EX: 1.0mm (0.039 in) 3, Measure the valve length. Length ‘Standard IN: 111.89mm (4.4051 in) EX: 111.69mm (4.3972 in) Minimum IN: 111.49mm (4.3894 in) EX: 111.29mm (4.3815 in) 4, Measure the valve stem diameter, Diameter IN : 8.030—8.045mm (0.3161—0.3167 in) EX: 6.025—8.040mm (0.3159—0.3165 in) 5. Measure the valve guide inner diameter. Inner diameter IN : 8.07—8.09mm (0.3177—0.3185 in) EX: 8.07—8.09mm (0.3177—0.3185 in) 6. Measure the valve stem-to-guide clearance. (1) Method No.1 ‘Subtract the outer diameter of the valve stem from the inner diameter of the corresponding valve guide. B1-35,INSPECTION AND REPAIR (2) Method No.2 Measure the valve stem play at a point close to the valve guide with the valve lifted slightly off the vaive seat. Clearance IN : 0,025—0,060mm (0.0010—0.0024 in) EX: 0.030—0.065mm (0.0012—0.0026 in) ‘Maximum: 0.20mm (0.008 in) 7. lithe clearance exceeds the maximum, replace the valve andlor valve guide. 8. Check the valve guide projection height (dimension Ain the VALVE GUIDE figure). Replace it necessary. our Height: 19.1—19.6mm (0.752—0.772 in) Replacement of valve guide OO | Note [| Although the shapes of the intake and exhaust valve guides are different, use the exhaust valve guide on — J ih} NW x both sides as a replacement. Removal Remove the vaive guide from the side opposite the combus- tion chamber with the SST. EarINSPECTION AND REPAIR Q°0 ° Kar Sa ee SBC Installation 1, Assemble the SST so that the depth L is as specified. Depth L: 19,1—-19.6mm (0.752—0.772 in) 2, Tighten the locknut. 3, Tap a new valve guide in from the side opposite the com bbustion chamber until the SST contacts the cylinder head. 4, Check thatthe vaive guide projection height is within spect cation. 5. IF not within specification, repeat steps 1—4. Valve Seat 1. Inspect the contact surface of the valve seat and valve face for the following (1) Roughness: (2) Damage 2. Irnecessary, resurface the valve seat with a 45° valve seat cutter and/or resurtace the valve face. 8. Apply a thin coat of Prussian blue to the valve face. 4, Check the valve seating by pressing the valve against the seat (1) If blue does not appear 360° around the valve face, re- place the valve. @ If blue does not appear 360° around the valve seat, resurface the seat. 5. Check the seat contact width. Width: 1.2—1.6mm (0.047—0,063 in) B1-37Bi INSPECTION AND REPAIR 6. Check that the valve seating position is at the center of the valve face. (1) Ifthe vaive seating position is too high, correct the valve seat with a 60° cutter. (Ifthe vaive seating position is too low, correct the valve seat with @ 25° (IN) or 15° (EX) cutter. 7. Seat the valve to the valve seat with a lapping compound, VALVE SEAT wioTs (amy 8. Check the sinking of the valve seat, Measure protruding length (dimension L) of each valve stem, Dimension L. IN: 46.5mm (1.831 in) EX: 46.5mm (1.831 in) (1) if Lis as below, it can be used as it is. IN : 46.5—47.0mm (1.831—1.850 in) EX: 46.5—47.0mm (1.831—1.850 in) (2) IfLis as below, insert a spacer between the spring seat and cylinder head to adiust. IN: 47.0—48.0mm (1.850—1.890 in) EX: 47.0—48.0mm (1.850—1.890 in) (8) If Lis more than as below, replace the cylinder head, IN: 48.0mm (1.890 in) EX: 48.0mm (1.890 in) aaa 7 Valve Spring 1. Inspect each valve spring for cracks or damage. 2. Cheok the tree length and out of square. Replace it necessary. Free length Standard Outer: 52.0mm (2.047 in) Inner: 44.0mm (1.732 in) Minimum Outer: 50.4mm (1.984 in) Inner: 42.7mm (1.681 in) Out of square ‘Outer: 1.8mm (0.07 in) max. Inner: 1.5mm (0.06 in) max. VARIATION FROM PERPENDICULAR, BUST OsINSPECTION AND REPAIR B1 Camshaft 1. Set the front and rear journals on V-blacks, Check the camshatt runout. Replace it necessary. eS Runout: 0.03mm (0.0012 in) max. 2. Check the cam for wear or damage. Replace i necessary. | 3, Check the cam lobe height at the two points as shown, Height IN : 38.059mm (1.4984 in) © EX: 38.059mm (1.4984 in) Minimum IN : 37.859mm (1.4905 in) + EX: 37.859mm (1.4905 in) aaa 4. Measure the journal diameters in X and Y directions at the two points (A and B) as shown, Diameter No.1 and No.5: 31,940—31.965mm (1.2575—1.2584 in) No.2, No.3 and No.4: 31.910—31.935mm (1.2563—1.2573 in) Out-of-round: 0.05mm (0.002 in) max. wusi7 —_§, Measure the oil clearance of the camshaft and camshaft eee eae eee et (1) Remove any oil, or dirt from the journals and bearing surface. (2) Set the camshaft on the cylinder head. (3) Position the Prastigauge on top of the journals in the axial direction (4) Place the camshaft caps and rocker arm shatts in pos- tion; then tighten them to the specified torque. Tightening torqu 18—26 Nem (1.8—2.7 m-kg, 13—20 fib) uma (6) Remove the camshaft caps and measure the oil clear- ance at each cap. Oil clearance No.1 and No.5: 0.035—0.085mm (0.0014—0.0033 in) No.2, No.3 and No. 0.065—0.115mm (0.0026—0.0045 in) Maximum: 0.15mm (0.006 in) (6) I the oll clearance exceeds the maximum, replace the ma cylinder head Bi-39 aLwine TET INSPECTION AND REPAIR 6. Measure the camshaft end play. fit exceeds the maximum, replace the camshaft or the cylinder head, End play: 0.08—0.16mm (0.0031—-0.0063 in) Maximum: 0.20mm (0.008 in) Rocker Arm and Rocker Arm Shaft 1. Check for wear or damage to the contact surfaces of the rocker arm shaft and the rocker arm. Replace if necessary. 2. Check the oil clearance between the rocker arm and shaft. Replace if necessary. (1) Measure the rocker arm inner diameter. Diameter: 18.000—16.027mm (0.6300—0.6310 in) (2) Measure the rocker arm shaft diameter. Diameter: 15.966—15.984mm (0.6286—0.6293 in) (@) Subtract the shaft diameter from the rocker arm di- ameter. clearance: 0.016—0.061mm (0.0006—0.0024 in) Maximum: 0.10mm (0.004 in) Hydraulic Lash Adjuster (HLA) ‘Check the HLA face for wear or damage. Replace if necessary. Caution ‘Do not remove the HLA unless necessary because oil leakage will occur if the O-ring is damaged. Cylinder Block 1. Check the cylinder block. Repair or replace if necessary. (1) Leakage damage (2) Cracks ) Scoring of wall 2. Measure the distortion of the top surtace of the cylinder block in the six directions as shown in the figure. Distortion: 0.1mm (0.006 in) max.INSPECTION AND REPAIR Bi 3, Ifthe distortion exceeds the maximum, repair by grinding, ‘0 replace the cylinder block. Height: 301.5mm (11.87 in) Grinding: 0.20mm (0.008 in) max. CFO ? v & 4 os eo | alles igs aaa seve 4. Measure the cylinder bore in X and ¥ directions at three levels (A, B, and C) in each cylinder as shown. SE S55 Tae | Olinger pore m9) a “ : Bore i: Sims Diameter a a Sandra 36.005 58.08 6. 3856—B.5606) owas eee 0.25 (0010) oversze | _ 66250—06.260 (9.:957—a.5064) y T 0.50 (0.020) oversize 36.500~86 519 (640663 4065) (1) Ifthe cylinder bore exceeds the maximum, rebore the cylinder to oversize. @) Kf the difference between the measurements A and C exceeds the maximum taper, rebore the cylinder to oversize. ‘Taper: 0.019mm (9.0004 in) max. @ If the difference between the measurements X and Y exceeds the maximum out-of-round, rebore the cylin- der to oversize, Out-of-round: 0.010mm (0.0004 in) max. Caution ‘The boring size should be based on the size of an over- size piston and be the same for all cylinders. 5. If the upper part of the cylinder wall shows uneven wear, remove the ridge with a ridge reamer. B1-41B1 INSPECTION AND REPAIR: Piston 1. Inspect the outer circumferences of all pistons for seizure or scoring. Replace if necessary. * 2, Measure the outer diameter of each piston at a right angle (80°) to the piston pin, 18.0mm (0.709 in) below the oil ring iand lower edge. OL ANG ‘GROOVE orn, Ch Piston diameter a Goren oaweren [S20 Piston Diameter i [Standard | 5.944—25.964 @.3696—3.3844) | sania — F925 (0.010) averize 86. 194— 86.214 @.9995~3.3842) a ‘0150 (0.020) oversize 26 aad—06 464 (4053-84081) 3, Check the piston-to-cylinder clearance, Clearance: 0.043—0.062mm (0.0017—0.0024 in) _ Maximum: 0.15mm (0.006 in) 4, Ifthe clearance exceeds the maximum, replace the piston or rebore the cylinders to fit oversize pistons. —[Fcurarance| ee If the piston Is replaced, the piston rings must also be replaced. Piston and Piston Rings 1. Measure the piston ring toring land clearance around the == entire circumference by using a new piston ring. Clearance (Top and Second): 0.03—0.07mm (0.0012—0.0028 in) Maximum: 0.5mm (0.006 in) Ifthe clearance exceeds the maximum, replace the piston Inspect the piston rings for damage, abrormal wear, oF breakage. Replace it necessary. [ol] 4, Insert the piston ring into the cylinder by hand and use the : piston to push it fo the botiom of the ring travel 7 [PISTON AING '5. Measure each piston ring end gap with a feeler gauge. Re- i place if necessary. End gap Top: 0.20—0.35mm (0.008—0.014 in) Second: 0.15—0.30mm (0.006—0.012 in) Oil rail :_0.20—0.70mm (0.008—0.028 in) ce Maximum: 1.0mm (0.039 in) TaLOET IINSPECTION AND REPAIR B1 Tae Waa Piston and Piston Pin 1, Measure the piston pin hole diameter in X and Y directions at four points. Diameter: 21.988—21.998mm (0.8657—0.8661 in) 2. Measure the piston pin diameter in X and Y directions at four points. Diameter: 21.974—21.980mm (0.8651—0.8654 in) 3. Check the piston pin-to-piston clearance. Clearance: 0.008—0.024mm (0.0003—0.0009 in) 4. ifthe clearance exceeds the specification, replace the pis- ton and/or piston pin, Connecting Rod 1, Measure the connecting rod small end bore. Diameter: 1.943—-21.961mm (0.8640—0.8646 in) 2. Check the interference between the small end bore and pis- ton pin, Interference: 0.013—0.037mm (0.0005—0.0015 in) 8. Check each connecting rod for bend. Repair or replace if necessary, Bend: 0.24mm (0.0094 in) max. Length (Center to Center): 158.45—158.55mm (6.2382—6.2421 in) I the connecting rod is replaced, the connecting rod cap and bolts must also be replacced because they are a matched set. Crankshaft 1. Check the journals and pins for damage, scoring, or oil hole clogging. 2, Set the crankshaft on Veblocks. 8. Check the crankshaft runout at the center journal. Replace it necessary. Runout: 0.03mm (0.0012 In) max. B1-43We Sao (CARANKPIN JOURNAL MAIN JOURNAL Sa FILLET ROLL. Taco wT INSPECTION AND REPAIR 4, Measure each journal diameter in X and Y directions at two places. Main journal Diameter: 59.937—59.955mm (2.3597—‘ Out-of-round: 0.05mm (0.0020 in) max. 3604 in) Crankpin journal Diameter: 50.940—50,955mm (2.0055—2.0061 in) ‘Out-of-round: 0.05mm (0.0020 in) max. 5, Ifthe diameter is below the minimum, grind the journals to maich an undersize bearing, Undersize bearing: 0.25mm (0.010 in), 0,50 mm (0.020 in), 0.75mm (0.030 in) Main Journal diameter undersize men fo) Bearing 828) “Joural ameter 0.25 (@.ot0)| No12a5 | _Sa6as—59.711 (2s601—2 3508) undersize [Nos '59.687—59.706 (2.24082, 3506) 0.50 (0.020)| Nai2.45 | __s0.449—60.461 (2.9409—2.3410) vundetsize [Nos 39,437—59.455 (2.5400—2.3407) f.75 (0.030)| No.12,48 | 59.193—88.211 (2.8904—2.911) ungersize [Nod 59,167—65.205 @.3902—2.3009), Crankpin journal diameter undersize arn Tourtal Tames 56 5B0—50 705 (1.99571 9965), 150 440-50 455 (1 9858—1.9964), 50.190 50.206 (7,9760—1.9768), Bearing 825, 025. (.010) undsrae (0.50 (0.020) undersze (0.75 (0.030) undersze Caution Do not grind the fillet roll. Main Bearing and Connecting Rod Bearing ‘Check the main bearings and the connecting rod bearings for peeling, scoring, or other damage. Timing Belt 1. Replace the timing belt if there is any oil or grease on it 2. Check the timing belt for damage, weer, peeling, cracks, or hardening. Replace #f necessary.INSPECTION AND REPAIR B1 Ne< Las (1.0 9) min maar Eo waa sa Caution a) Never forcefully twist turn inside out, or bend the timing belt. b)Be careful not to allow oil or grease on the belt. Timing Belt Tensioner and Idler Pulley Check the timing bett tensioner and idler pulley for smooth rotation and abnormal noise. Replace if necessary. Caution Do not clean the tensioner with cleaning fluids. If necessary, use a soft rag to wipe it clean, and avoid scratching it. Timing Belt Tensioner Spring Check the tree length of the tensioner spring. Replace if necessary, Free length: 63.0mm (2.480 In) Timing Belt Pulley and Camshatt Pulley Inspect the pulley teeth for wear, detormation, or other dam- age. Replace i necessary. Caution Do not clean the pulley with cleaning fluids. If neces- ary, use a rag to wipe it clean. Timing Belt Cover (lower and upper) Inspect the timing belt covers for damage or cracks. Replace if necessary, B1-45B1 ASSEMBLY | | ASSEMBLY f PREPARATION | Sst ' 1 r |] ao.011 010 491.011 001 | 8 ly 11 ch 49.011 08 | | Piston pin seting ‘Support block | |_| suppor block | | foto RS | By feud | RO a ee SS ® SS © | ao Lor ono) £8 L011 040) {| 49 toit ooo | 49 L011 005 49 L011 006 EAN) sore Stopper bot Puller & instar oo || are fara Gavel i eae) Re, | Etat one Sie) > ul fy: | | 49L011 008 49 LO11 010 49. LO1T O11 f a | | Guide ‘Centering tool Holder || eats S Gara Rea ee 8 © [SSS om Sots ono, SS tott ox eit it | | aocons 140 49 L012 010 aE | 49.012 001 — were o@cBie lee QUCDB (|s view ae Can't ~ | ave gave (ote oan | | | ae vote 2 45 1012 008 450598 1008 £ | @an of Pant of ® titer . | | Stoke oso {eo Loke oxo) et | aT | |e coso 222 so se01 310 ff | Pivot, valve Centering tool, U1 Soioine seer ase i t |; ; | 1. Clean all parts before reinstallation. | | Z.Rbpy new engine of to al siding and rotting pats E | 3. Replace plain bearings if they are peeling, burned, or otherwise damaged. {| 4. Tighten all bolts and ruts to the specitied torques. | Caution {| Do not reuse gaskets or oil seals. B1-46ASSEMBLY (CYLINDER BLOCK) B1 CYLINDER BLOCK I Torque Specifications Connecting Rod 1, Assemble the SST as shown. B1-473, Tighten the locknut. B1 ASSEMBLY (CYLINDER BLOCK) | 2. Set the stopper bolt (49 L011 005) so that the depth L is | as specified. if a Depth L: 59.5—59.7mm (2.342—2.450 in) 4, Insert the SST No.2 into the piston pin as shown and fully sorew in the SST No.1 5. Apply engine oil to the piston pin. : Bina ei 6. Set the piston on the SST with the F mark facing upward. : on, HOLE 7. Align the oil hole of the large end of connecting rod and | iF T F mark on the piston as shown in the figure. 8, Press the pision pin into the piston and connecting rod un- {il the SST contacts the stopper bot. 9, While inserting the piston pin, check the pressure force. If itis less than speciied, replace the piston pin or the con necting rod. Ste Pressure force: 4,905—14,715 N (500—1,500 kg, 1,100—3,300 Ib) 10. Check the oscillation torque of the connecting rod. (Refer to page 81-32,) BNE Piston Ring 1. Install the three-piece oll rings on the pistons. (1) Apply engine oil to the oil ring spacer and ral, (@) Install the oil ring spacer so that the opening faces upward. (G) Install the upper rail and lower ral Note any 2) The upper rail and lower rail are the same. b) Each rail can be installed with either face upward. wasn Bi-48ASSEMBLY (CYLINDER BLOCK) B1 SPACER TANG ‘SPACER ENDS PISTON UPPER Rat coe BERS ae lL Ne UPPER RAIL eo ou ne cia ‘SPACER ad oi aN SECOND TOWER RAL Ng ame ‘CENTER MAIN BEARING, ON THE a SIDE III VIDIYD )INDER BLOCK uae se Plasriaauae A] 2. Check that both rails are expanded by the spacer tangs ‘as shown in the figure by checking that both rails turn smoothly in both directions, 8. Install the second ring to the piston first; then install the top ring. Use a piston ring expander. Caution a) The ring must be installed so that the “R”” marks face upward. b) The second ring must be installed with the scraper face downward. 4. Apply a liberal amount of clean engine oil to the second and top piston rings. 5. Position the opening of each ring as shown in the figure. Crankshaft 4. Before installing the crankshaft, inspect the main bearing oil clearances as described, Note ‘The center main bearing on the cylinder block side has thrust shoulders. Oil clearance inspection (1) Remove any foreign material and oil from the journals and bearings. (2) Install the upper main bearings in the cylinder block. (@) Set the crankshatt in the cylinder block (4) Postion the Plastigauge on top of the journals in the axial direction Bi-49ASSEMBLY (CYLINDER BLOCK) (©) Install the main bearing caps along with the lower main earings according to the cap number and ¢ mark. ( Tighten the caps in two or three steps in the order in the figure. Tightening torque: 82—88 Nan (8.4—9.0 m-kg, 61—65 ft-lb) Caution Do not rotate the crankshaft when measuring the oil clearances. (7) Remove the main bearing caps, and measure the Plastigauge at each journal at the widest point for the smallest clearance, and at the narrowest point for the largest clearance. if the oll clearance exceeds specification, grind the crankshaft and use undersize main bearings. (Refer to page 81-44.) Oil clearance No.1,2,4,5: 0.025—0.043mm (0.0010—0.0017 in) No.3: 0.031—0.04amm (0.0012—0.0019 In) aussi «Maximum: 0.08mm (0.0031 in) 2, Apply a liberal amount of engine oil to the main bearings and main journals, 8. Install the crankshaft and the main bearing caps accord- ing to the cap number and + mark Co 4, Verify that the crankshatt rotates smoothly by hand. 6. Inspect the crankshaft end play. End play: 0.08—0.18mm (0,0031—0.0071 in) ‘Maximum: 0.30mm (0.0118 in) 6. If the end play exceeds specification, grind the crankshaft and use an undersize center main bearing. ‘ Center main bearing width i ‘Standard: 27.94—27.99mm (1.1000—1.1020 in) i (0.25mm (0.040 in) undersize: 28.04—28.09mm (1.1040—1.1059 in) 0.50mm (0.020 in) undersize: 28.12—28.17mm (1.1071—1.1091 in) ‘more 0.76mm (0,030 in) undersize: oe 28.20—28.25mm (1.1102—1.1122 in) rust width Is available only in undersize cen- bearing rasASSEMBLY (CYLINDER BLOCK) B1 Pilot Bearing 1. Apply engine oil o the outer citcumference of the bearing. 2. Seta piece of pipe (outer diameter 30—-S4mm, 1.181.834 in) against the outer race of the bearing; then tap it evenly into the crankshatt. 3. Lubricate the bearing with grease Piston and Connecting Rod Assembly 1. Apply a liberal amount of clean engine oil to the oylinder walls, pistons, and rings. 2. Check the piston rings for the end gap alignment 3. Insert each piston assembly into the cylinder block with the F mark facing the front of the engine. Use a piston installer tool (commercially available). Connecting Rod Cap 1. Check the connecting rod bearing clearances using the ‘same procedure as used for the main bearing oil clearance, Connecting rod cap tightening torque: 65—69 Nin (6.6—7.0 m-kg, 48—51 ft-tb) Oil clearance: 0.027—0.067mm (0.0011—0.0026 in) ‘Maximum: 0.10mm (0.004 in) Caution Align the matching marks on the cap and on the con- necting rod when Installing the connecting rod cap. 2, Ithe oil clearance exceeds specification, grind the crank shaft and use undersize bearings. (Refer to page B1-44,) 3. Check the side clearance of each connecting rod without the cap installed. Side clearance: 0.110—0.262mm (0.0043—0.0103 in) Maximum: 0.30mm (0.012 in) IW the clearance exceeds the maximum, replace the con- ecting rod, B1-51Bi ASSEMBLY (CYLINDER BLOCK) 4. Apply a liberal amount of engine oil to the crankpin journal ‘and connecting rod bearing. 5. Install the connecting rod cap with the alignment marks ~ aligned. Tightening torque: ‘@5—69 Nm (6.6—7.0 m-kg, 4851 ft-lb) 6. Verity that the crankshaft rotates smoothly by hand. aE |CYLINDER BLOCK TI [Torque Specifications 70-12m (0120 emg, 69104 nie) L 10-26 (1-27, 13-20) (10120 emg, 61—108 i) No og,ASSEMBLY (CYLINDER BLOCK) B1 SST Ba Rear Cover 1. Apply engine oil to the rear cover and new oil seal lip. 2. Fit the oil seal onto the rear cover. ‘3. Press the oil seal in evenly using & suitable pipe Oil seal outer diameter: 110mm (4.33 in) Caution The oil seal must be pressed in until it is flush with the edge of the rear cover. 4. Install the rear cover and a new gasket. Tightening torque: 7.8—12 Nm (80—120 cm-kg, 69—104 in-tb) 5. Cut away the portion of the gasket that projects out from the rear cover assembly toward the oil pan side. Caution Do not scratch the rear cover assembly. End Plate Install the end plate, Tightening torque: 19—30 Nm (1.9—3.1 m-kg, 14-22 ft-lb) oil Pump 41. Apply engine cil 1o the oil pump body and new oil seal lip. 2. Fit the oil seal onto the ol pump body, 4. Press the oll seal in evenly using a suitabie pipe. Oil seal outer diameter: 48mm (1.89 in) Caution The oil seal must be pressed in until it is flush with the edge of the oil pump body, B1-53ASSEMBLY (CYLINDER BLOCK) 4. Apply engine oil to the oil seal lip. 5, Remove any dirt or other material from the contact surfaces, 6. Apply a continuous bead of silicon sealant to the contact surface of the oil pump. 7. Install a new O-ting into the pump body. Caution Do not allow any sealant to get into the oil hole. 8. Install the oil pump. Tightening torque @: 18-25 Nm (1.92.6 m-kg, 14—19 ftb) ©: 37—52 Nm (3.8—5.3 m-kg, 27—38 ftb) 9. Remove any sealant which has been squeezed out. Stiffener 4, Remove any dirt or other material from the contact surface. 2. Apply a continuous bead of silicone sealant to the stiffener along the inside of the bolt holes, and overlap the ends. 3. Install the stitfener. Tightening torque: 6.9—12 Nin (70—120 cm-kg, 61—104 In-b) Caution After the sealant is applied, the oil pan must be se- ‘cured within 30 minutes. Oil Strainer Install the oil strainer and a new gasket. Tightening torque: 7.8—12 Nin (80—120 cm-kg, 69-104 1b) Oil Pan 1. Apply @ continuous bead of silicone sealant to the ol pan ‘around the inside of the bolt holes and overlap the ends. 2. Install the cil pan, Tightening torque: 6.9—12 Nam (70—120 om-kg, 61—104 in-Ib)ASSEMBLY (CYLINDER BLOCK) B1 Flywheel (M/T), Drive Plate (A/T) 1, Remove any old sealant from the bolts and bolt holes. If ald sealant cannot removed from the bolt, replace it 2. Apply sealant to the bolt threads. (Mm) 3, Install, and tighten the fywheel with the SST. Tightening torque: 96—103 Nan (9.8—10.5 m-kg, 71—76 ft-lb) an, 4, Install, and tighten the drive plate adapter, drive plate, and backing plate with the SST. Tightening torque: ‘96—103 Nm (9.8—10.5 m-kg, 71—76 ft-lb) Clutch Disc and Clutch Cover (M/T) Install the clutch disc and clutch cover using the SST. (Refer to Section 1) Tightening torque: 18—26 Nm (1.8—2.7 m-kg, 13—20 ft-lb) Water Pump 1. Remove all din, grease, and other material from the water pump mounting surface. 2. Place a new gasket in position B1-55ASSEMBLY (CYLINDER HEAD) 3, Install the water pump. Tightening torque: 19—25 Nm (1.92.6 m-kg, 14—19 ft-lb) Tame 23-290m Go40 ema, 26-95 nb) GASKET, REPLACE CS ay 3 8 & be